阅读说明：本技术 层压组件、包括这种组件的尿布和用于制造这种组件的方法 (Laminate assembly, diaper comprising such an assembly and method for manufacturing such an assembly ) 是由 皮埃尔-伊夫·弗朗索瓦·让·利诺 于 2019-03-20 设计创作，主要内容包括：本发明涉及一种层压组件,该层压组件包括支撑层(32)和防滑条(34),防滑条(34)包括弹性体材料,支撑层(32)和防滑条(34)被层压在一起,防滑条(34)包括基部(34A)和从基部(34A)延伸的多个突出元件(34B),并且多个突出元件(34B)从层压组件(30)的表面(30A)突出。本发明还涉及一种包括这种层压组件(30)的尿布和一种用于制造层压组件(30)的方法。本发明还涉及一种包括这种组件的尿布和一种用于制造这种组件的方法。(The present invention relates to a laminate assembly comprising a support layer (32) and a cleat (34), the cleat (34) comprising an elastomeric material, the support layer (32) and the cleat (34) being laminated together, the cleat (34) comprising a base (34A) and a plurality of projecting elements (34B) extending from the base (34A), and the plurality of projecting elements (34B) projecting from a surface (30A) of the laminate assembly (30). The invention also relates to a diaper comprising such a laminate assembly (30) and to a method for manufacturing a laminate assembly (30). The invention also relates to a diaper comprising such an assembly and to a method for manufacturing such an assembly.)

1. A laminate assembly (30) comprising a support layer (32) and a cleat (34), the cleat (34) comprising an elastomeric material, the support layer (32) and the cleat (34) being laminated together, the cleat (34) comprising a base (34A) and a plurality of projecting elements (34B) extending from the base (34A), and the plurality of projecting elements (34B) projecting from a surface (30A) of the laminate assembly (30).

2. The laminate assembly (30) of claim 1 wherein the support layer (32) comprises a nonwoven web (36, 38).

3. The laminate assembly (30) of claim 1 or 2, wherein the support layer (32) comprises a thermoplastic film.

4. The laminate assembly (30) of claim 3, wherein the thermoplastic film is an elastomeric film (40).

5. The laminate assembly (30) of claim 4, wherein the base (34A) of the cleat (34) and the elastic film (40) each have a width, the width (L34A) of the base (34A) being less than the width (L40) of the elastic film (40), preferably the width of the base being greater than or equal to 10% and less than or equal to 60% of the width of the elastic film.

6. The laminate assembly (30) of claim 4 or 5, wherein the support layer (32) comprises a first nonwoven web (36), a second nonwoven web (38), and the elastic film (40), the elastic film (40) being laminated between the first nonwoven web (36) and the second nonwoven web (38).

7. Laminate assembly (30) according to any one of claims 1 to 6, wherein, in a rest state, in the region comprising the protruding elements (34B), the cleats (34) have a static coefficient of friction, measured according to the standard ASTM D1894, greater than or equal to 0.1, preferably greater than or equal to 0.5, even more preferably greater than or equal to 0.8, and less than or equal to 10, preferably less than or equal to 5, even more preferably less than or equal to 3, in the direction MD and/or in the direction CD.

8. Laminate assembly (30) according to any one of claims 1 to 7, wherein the cleats (34) have a static coefficient of friction measured according to the standard ASTM D1894, comprised between 50% and 150% of the static coefficient of friction in the rest condition when the cleats (34) are stretched to 15% of the rest value.

9. The laminate assembly (30) according to any one of claims 1 to 8, whereinA protruding element density of the plurality of protruding elements (34B) in a resting state being greater than or equal to per cm²3 projecting elements, preferably greater than or equal to per cm²10 projecting elements and less than or equal to per cm²400 projecting elements, preferably less than or equal to per cm²300 protruding elements.

10. The laminate assembly (30) according to any one of claims 1 to 9, wherein, in a resting state, the plurality of projecting elements (34B) have a pattern comprising a repeating cleat pattern (44).

11. The laminate assembly (30) according to any one of claims 1 to 10, wherein the sum of the areas defined on the base (34A) by orthogonal projection of the protruding elements (34B) on the base (34A) is greater than or equal to 1%, preferably greater than or equal to 5%, and less than or equal to 40%, preferably less than or equal to 35%, of the total area of the base of the cleat pattern (44).

12. The laminate assembly (30) according to any one of claims 1 to 11, wherein the base (34A) has a thickness (E34A) greater than or equal to 10 μ ι η, preferably greater than or equal to 15 μ ι η, and less than or equal to 200 μ ι η, preferably less than or equal to 150 μ ι η.

13. The lamination assembly (30) according to any one of claims 1 to 12, wherein the protruding elements (34A) are pins and/or studs and/or rods, each rod having a head disposed at an end of the rod opposite the base.

14. An absorbent article, such as a disposable diaper, comprising a laminate assembly according to any of the preceding claims.

15. A method for manufacturing a laminated assembly (30), the method comprising the steps of:

-forming a cleat (34) by dispensing elastomeric material in a forming device (100), the cleat comprising a base (34A) and a plurality of protruding elements (34B) extending from the base (34A);

-assembling the support layer (32) and the cleats (34) by laminating the support layer (32) and the cleats (34).

Technical Field

The present disclosure relates to laminate assemblies that may be used in the hygiene field, particularly absorbent articles, especially for making elastic ears for diapers.

Background

Disposable diapers are typically composed of an absorbent central portion including at each end a front waistband portion having two front ears and a back waistband portion having two back ears for attaching the diaper to the wearer of the disposable diaper. Each back ear is usually provided with a retaining means, for example with a hook, which cooperates with an application area arranged on the front belt. In the hygiene field, this application area is commonly referred to as the "landing area", or in french terms, as the "comfort zone".

However, due to movement of the diaper wearer, the diaper may sag at the ears and/or the front ears may move relative to the back ears. Such sagging and/or shifting can cause discomfort to the diaper wearer and/or cause undesirable leakage.

Disclosure of Invention

The present invention aims to remedy at least some of these disadvantages.

To this end, the invention relates to a laminate assembly comprising a support layer and a cleat, the cleat comprising an elastomeric material, the support layer and the cleat being laminated together, the cleat comprising a base and a plurality of projecting elements extending from the base, and the plurality of projecting elements projecting from a surface of the laminate assembly.

By means of the cleats, in particular the projecting elements, the displacement of the other surface relative to the cleats is reduced when the laminate assembly is in contact with the other surface. However, the projecting elements do not allow the cleat to engage and hook with the other surface. For example, cleats make it impossible to hang 1kg (kilogram) of weight for a period of 10 seconds. In some cases, the 180 ° peel force of the cleats is less than or equal to 0.02N, and in some cases equal to 0N.

The direction MD refers to the machine direction and to the direction of travel of the cleats in the machine during manufacture of the cleats, and the direction CD refers to the cross direction and to the direction perpendicular to the direction MD.

The "180 ° peel" method is a method for measuring the peel force, i.e., the force separating the laminate assembly from the application area. This method is described below.

Conditioning of samples-test samples were conditioned at 23 ℃ ± 2 ℃ and 50% ± 5% relative humidity for 2h (hours).

Preparation of cleats-cleats are typically used in the direction MD. The cleats are typically in the form of belts, the length of which is in the direction MD. Bonding a portion of the tape in the MD to 80g/cm²And applying or rotating a 2kg (kilogram) roller on the cleats in one direction, and then applying or rotating the roller in the other direction (back and forth) along the entire length of the belt portion at a speed of about 700mm/min (millimeters/minute). The paper and cleats were cut with scissors into strips 25.4mm (millimeters) wide in the direction MD. The length of each paper strip is 210mm, and the anti-slip strip is located in the center of the paper.

Preparation of application area-application area the sample has a width in the direction MD of 50mm and a maximum length of 200mm and is cut in half longitudinally.

Assembly-place the strip on the application area sample so that the cleats are centered on the application area sample. A 2kg (kilogram) roller was applied or rotated on the cleats in one direction and then applied or rotated in the other direction (back and forth) along the entire length of the belt at a speed of approximately 700 mm/min. The application area sample was placed in the clamp of the cradle, the cut side was placed in the clamp, and a 1kg weight was hung from the lower portion of the tape for 10 seconds (seconds). The weight was then removed. This step ensures that the cleats and application area samples are assembled.

Measure-then place the assembly in a tensile tester with 100N (newton) measuring cells. The strip is inserted into the upper (movable) jaw. The reading of the load cell is set to zero. The application area sample was inserted into the lower jaw (stationary) and slight tension was applied. The force must be between 0.02N and 0.05N. During insertion, the spacing of the jaws was 50 mm. The assembly is centered between the two jaws. The test was performed with a constant displacement at a speed of 305mm/min, the test stroke being 50 mm. The test stroke is adjusted according to the width of the holding device to be tested.

Since the cleats are made of an elastomeric material, the cleats are elastic. The elasticity of the cleats imparts elasticity to the laminate assembly. Thus, when a laminate assembly is used, the laminate assembly can be stretched while the cleats themselves are stretched. Stretching of the laminate assembly allows for example the application of a pressure when attaching the disposable diaper to a wearer that is greater than the pressure applied by the laminate assembly without stretching. This higher pressure also reduces the risk of the surface in contact with the cleats moving and/or shifting relative to the cleats.

Since the cleats are made of an elastomeric material, they are soft to the touch for both the wearer and the person handling the diaper and minimize the risk of skin irritation.

As non-limiting examples of elastomeric materials, mention may be made of: styrene/isoprene (SI), styrene/isoprene/Styrene (SIs), styrene/butadiene/styrene (SBS), styrene-ethylene/butylene-styrene (SEBS), styrene-ethylene/propylene-styrene (SEPS) or SIBS copolymers. Mixtures of these elastomers with each other or with non-elastomers may also be considered, so as to modify certain properties other than elasticity. For example, to modify certain properties of the substrate (elasticity, heat resistance, processability, uv resistance, coloration, etc.), up to 50% by weight (or mass%) but preferably less than 30% by weight (or mass%) of a polymer, such as polyethylene styrene, polystyrene or poly-alpha-methylstyrene, epoxy polyesters, polyolefins, such as polyethylene or certain ethylene/vinyl acetates, preferably of high molecular weight (higher molar mass) may be added.

The elastomeric material may in particular be styrene-isoprene-styrene, which may be available, for example, from KRATON Polymers under the name KRATON D (registered trademark), or from DEXCO Polymers LP under the name VECTOR SBC 4211 (registered trademark). Thermoplastic elastomer (TPE) materials, particularly thermoplastic polyurethane elastomers, including pellettane (registered trademark) 2102-75A from the dow chemical company may also be used. Styrene-butadiene-styrene may also be used, including KRATON D-2122 (registered trademark) from Kraton Polymers, or VECTOR SBC 4461 (registered trademark) from Dexco Polymers LP. Alternatively, styrene-ethylene/butylene, including KRATON G-2832 (registered trademark) from KRATON polymers, or styrene-ethylene-butylene-styrene (SEBS) block copolymers, including KRATON (registered trademark) G2703.

This list is not exhaustive and can be accomplished by using all of the following: hydrogenated polyisoprene polymers, such as styrene-ethylene-propylene-styrene (SEPS), styrene-ethylene-propylene-styrene-ethylene-propylene (sepsepsep); hydrogenated polybutadiene polymers, such as styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-butylene (sebsebsebseb), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-isoprene-butadiene-styrene (SIBS); hydrogenated polyisoprene/butadiene polymers such as styrene-ethylene-propylene-styrene (SEEPS); and commercially available vinyl hydrogenated polyisoprene/polystyrene triblock polymers such as HYBRAR 7311(kuraray america, inc., Houston, Tex.), and combinations thereof.

Configurations of polymer blocks, such as diblock, triblock, multiblock, star, and radial, are also contemplated in this disclosure. In some cases, higher molecular weight (or molar mass) block copolymers may be desired. The block copolymer may be available from Kraton Polymers U.S. LLC of Houston, Tex, under the names of, for example, Kraton MD6716, Kraton D1102, Kraton SIBS 1102, Kraton D1184, Kraton FG1901 and Kraton FG1924, and from Septon Company of America, Pasadena, Tex, under the names of Septon 8007, Septon V9827 and Septon 9618. Dynasol from spain is another potential supplier of these polymers. In particular, kraton md6716 SEBS triblock polymers are particularly suitable for the present disclosure.

Copolymers of isooctyl acrylate and acrylic acid with a monomer ratio of 90/10, which are thermoplastics with physical crosslinking in the absence of crosslinking agents, can also be used. A polyamide polyester block copolymer PEBAX (registered trademark) 2533 from Arkema may also be used.

Other possible materials are polyolefin polymers with elastomeric properties, mainly copolymers of ethylene and/or propylene, especially from metallocene-catalyzed substances, such as VISTA AXX VM-1120 (registered trademark), available from Exxon Mobil Chemical, or rubber-filled polymers, such as EPDM-filled Santoprene.

Examples of polyolefin-based thermoplastic elastomers suitable for use in the elastomeric film layer include, inter alia, crystalline polyolefins, e.g., homopolymers or copolymers of alpha-olefins having from 1 to 20 carbon atoms and including from 1 to 12 carbon atoms.

The homopolymers and copolymers described below are examples of crystalline polyolefins.

(1) Ethylene homopolymers, ethylene homopolymers can be prepared by any low pressure and high pressure process.

(2) Copolymers of ethylene with up to 10 mole% of an alpha-olefin other than ethylene or vinyl monomers such as vinyl acetate and ethyl acrylate; for example, ethylene octene copolymers are available under the trade name Engage 8407 or Engage8842(Dow Chemical, Houston, Tex).

(3) A propylene homopolymer; examples include polypropylene impact copolymer PP7035E4 and polypropylene random copolymer PP9574E6(Exxon Mobil, Houston, Tex.).

(4) A random copolymer of propylene with not more than 10 mole% of an alpha-olefin other than propylene.

(5) A block copolymer of propylene with not more than 30 mole% of an alpha-olefin other than propylene.

(6) A homopolymer of butene-1-butene.

(7) A random copolymer of 1-butene with no more than 10 mole% of an alpha-olefin other than 1-butene.

8) 4-methyl-1-pentene homopolymer.

(9) A random copolymer of 4-methyl-1-pentene and not more than 20 mole% of an alpha-olefin other than 4-methyl-1-pentene.

The α -olefins include, for example, ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene and 1-octene.

Commercially available polyolefin-based thermoplastic elastomers for the elastomeric film layer include VISTA MAX. TM. (propylene-based elastomers available from ExxonMobil Chemical, Houston, Tex.), INFUSE. TM. (olefin block copolymers available from Dow Chemical Company, Midland, Michigan), VERSIFY. TM. (propylene-ethylene copolymers), such as VERSIFY. TM.4200 and VERSIFY. TM.4300(Dow Chemical Company, Midland, Michigan), ENGAGE. TM. (ethylene octane copolymers available from Dow Chemical, Houston, Tex.), and NOTIO 0040 and NOTIO 3560 (available from Mitsui Chemical (USA), New York, N.Y.), Adflex X100G (available from Lyondelsilcell).

In particularly suitable embodiments, the polyolefin-based thermoplastic elastomer is VISTAMAXX. tm.6102fl or VISTAMAXX 7050FLX (available from ExxonMobil Chemical, Houston, Tex.). The symbol "TM" of the registered trademark name corresponds to "trademark".

In another case, the thermoplastic elastomer may be a thermoplastic ester/ether elastomer or a thermoplastic polyurethane.

Elastomeric material refers to a material that can be stretched without breaking under the application of a tensile force applied in a given direction, and can substantially recover its original shape and size after release of the tensile force. For example, the elastomeric material is a film that retains, after elongation and release, a residual SET or residual (reference) of less than or equal to 30%, preferably less than or equal to 20%, even more preferably less than or equal to 10% of its initial dimension (before elongation) for an elongation of 100% of its initial dimension at room temperature (23 ℃ -c.) (residual SET is also referred to as "permanent SET" or "SET"). The elastomeric material may be a thermoplastic elastomeric material, in particular a physically cross-linked thermoplastic elastomeric material such as those described in the present disclosure, or a chemically cross-linked thermoplastic elastomeric material.

In some embodiments, at room temperature (23 ℃ -degrees celsius), the cleats have a residual deformation of less than or equal to 30% of their initial dimension (prior to elongation), preferably less than or equal to 20%, even more preferably less than or equal to 15%, even more preferably less than or equal to 10%, for an elongation of 100% of their initial dimension.

In some embodiments, at room temperature (23 ℃ -degrees celsius), the cleats have a residual deformation of less than or equal to 30% of their initial dimension (prior to elongation), preferably less than or equal to 20%, even more preferably less than or equal to 15%, even more preferably less than or equal to 10%, for an elongation of 100% of their initial dimension.

In some embodiments, the support layer is comprised of a nonwoven web (nonwoven web).

By nonwoven web is meant a product obtained by forming a web of consolidated fibers and/or filaments. Consolidation may be mechanical, chemical, or thermal and involves the presence of bonds between fibers and/or filaments. Such consolidation may be direct, i.e. directly between the fibers and/or filaments by welding, or indirect, i.e. through intermediate layers between the fibers and/or filaments, such as adhesion layers or adhesive layers. The term nonwoven refers to a tape-like or net-like structure of fibers and/or filaments interwoven in a non-uniform, irregular, or random manner. The nonwoven may be made from a variety of synthetic and/or natural materials. Examples of natural materials are cellulosic fibers such as cotton, jute, flax, etc., and may also include reprocessed cellulosic fibers such as rayon or viscose. Natural fibers for nonwoven webs can be prepared using various methods such as carding. Examples of synthetic materials include, but are not limited to, synthetic plastic polymers, which are known to form fibers, including, but not limited to: polyolefins such as polyethylene, polypropylene, polybutylene, and the like; polyamides such as polyamide 6, polyamide 10, polyamide 12, and the like; polyesters such as polyethylene terephthalate, polybutylene terephthalate, polylactic acid, and the like; a polycarbonate; polystyrene; a thermoplastic elastomer; a vinyl polymer; a polyurethane; and blends and copolymers thereof.

In some embodiments, the support layer may have a single layer structure or a multi-layer structure. The support layer may also be combined with another material to form a laminate. For example, the nonwoven may be a spunbond, spunmelt, thermobonded carded type of nonwoven, and the support layer may be SMS, SMMS, SS, SSs, SSMMS, SSMMMS, through air, or others. These examples are given in a non-limiting manner.

Nonwoven webs are formed, for example, from webs of fibers and/or filaments produced by dry-laid (dry), wet-laid (wet) or spun-laid techniques (melt/extrusion) and consolidated by mechanical, chemical and/or adhesive bonding.

The nonwoven web may be a calendered carded nonwoven.

A calender carded nonwoven is a nonwoven comprising a fibrous web having web consolidation points that are substantially uniformly distributed on the web by thermal consolidation. Consolidation ensures a certain cohesion of the fibers, allowing them to be handled and transported, in particular to be wound into rolls and unwound. Activation of the calendered carded nonwoven web makes it possible to lengthen and/or destroy the fibers of the nonwoven web and/or deform the consolidation points of the web. Thus increasing the elongation capability of the nonwoven web.

The fibers of the calendered carded nonwoven web are comprised between 1dTex and 8dTex, preferably between 1.3dTex and 6.7dTex, more preferably between 1.6dTex and 5.5 dTex.

Tex is the SI unit of the fineness of the textile fiber. It represents the weight of a 1000m (meter) fiber length.

In some embodiments, the support layer may comprise a nonwoven web forming an acquisition veil, particularly an acquisition veil of an absorbent article.

In some embodiments, the carrier layer may comprise a thermoplastic film.

Thermoplastic film refers to a film of thermoplastic material, which may be an elastic material or a non-elastic material.

A thermoplastic film of an elastic material refers to a film that can be stretched without breaking under the action of a tensile force applied in a given direction and that can substantially recover its original shape and dimensions after release of the tensile force. For example, a thermoplastic film of an elastomeric material is a film that retains a residual SET or residual after elongation and release of less than or equal to 30%, preferably less than or equal to 20%, even more preferably less than or equal to 10% of its initial dimension (before elongation) for an elongation of 100% of its initial dimension at room temperature (23 ℃) (residual SET is also referred to as "permanent SET" or "SET").

A thermoplastic film of a non-elastic material refers to a film that does not fall within the definition of a thermoplastic film of an elastic material.

When the thermoplastic film is made of a non-elastic material, the elasticity of the laminate assembly is imparted by the elastomeric material of the cleats, for example by using a weight of less than 30g/m²(grams per square meter) of a nonwoven fabric.

As non-limiting examples of thermoplastic materials, mention may be made of polyolefins, polyethylene, Linear Low Density Polyethylene (LLDPE), Low Density Polyethylene (LDPE), metallocene polyethylene (m-PE), High Density Polyethylene (HDPE), EVA (ethylene vinyl acetate) and PP (polypropylene), which comprise a monomodal or multimodal (for example bimodal) molecular weight (molar mass) distribution, in particular a composition comprising LLDPE and plastomers, in particular polyethylene-based plastomers. Polyamides (PA), polylactic acids (PLA), Polyhydroxyalkanoates (PHA), PVOH, PBS, polyesters, polyvinyl chloride (PVC) or Acrylonitrile Butadiene Styrene (ABS) may also be used.

In some embodiments, the thermoplastic film is an elastomeric film.

As a non-limiting example of the elastomeric material used to form the elastic membrane, mention may be made of the same elastomeric materials cited as non-limiting examples of elastomeric materials used to make the cleats.

In some embodiments, the elastic film may be formed of an elastic adhesive.

In some embodiments, the elastic membrane may include more than one layer or be a "skin layer," i.e., an elastic membrane covered by skin.

In some embodiments, the elastic film may be formed of an elastic adhesive.

In some embodiments, the elastic adhesive film may be extruded onto the nonwoven web and then laminated to the nonwoven web.

In some embodiments, the support layer is comprised of a nonwoven web and an elastic film.

In some embodiments, the base of the cleat and the elastic film each have a width, the width of the base being less than the width of the elastic film, preferably the width of the base is greater than or equal to 10% and less than or equal to 60% of the width of the elastic film.

In some embodiments, the area of the protruding element of the cleat and the base of the cleat each have a width, the width of the area of the protruding element being less than the width of the base of the cleat, preferably less than or equal to 60% of the width of the base, even more preferably less than or equal to 45% of the width of the base.

In some embodiments, the support layer may include a first nonwoven web, a second nonwoven web, and an elastic film laminated between the first nonwoven web and the second nonwoven web.

In some embodiments, in the rest state, in the region comprising the protruding elements, the cleats have a static coefficient of friction, measured according to standard ASTM D1894, greater than or equal to 0.1, preferably greater than or equal to 0.5, even more preferably greater than or equal to 0.8, and less than or equal to 10, preferably less than or equal to 5, even more preferably less than or equal to 3, in direction MD and/or direction CD.

By "at rest" is meant that the laminated assembly is not subjected to external forces, such as stretching forces. In other words, for example, in the diaper field, "at rest" means that the laminate is tested before first use by the end user, immediately after packaging, i.e., before the diaper is placed on a person. The measurement of the static friction coefficient may be performed in the longitudinal direction and/or in a lateral direction, which is orthogonal to the longitudinal direction. The measurement of the static friction coefficient may be performed in the direction MD and/or the direction CD.

The direction MD refers to the machine direction and to the direction of travel of the cleats in the machine during manufacture of the cleats, and the direction CD refers to the cross direction and to the direction perpendicular to the direction MD.

In some embodiments, the cleats have a static coefficient of friction measured according to standard ASTM D1894, comprised between 50% and 150% of the static coefficient of friction in the state of rest when the cleats are stretched to 15% of the value of rest.

The measurement of the static friction coefficient may be performed in the longitudinal direction and/or in a lateral direction, which is orthogonal to the longitudinal direction. The measurement of the static friction coefficient may be performed in the direction MD and/or the direction CD.

The dimension of the cleats in the direction MD is greater than the dimension in the direction CD.

In some embodiments, the cleats have a grammage per unit area greater than or equal to 10g/m²(g/m), preferably greater than or equal to 20g/m²And is less than or equal to 250g/m²Preferably less than or equal to 200g/m²。

In some embodiments, the support layers are bonded by adhesive bonding.

The adhesive may be applied continuously in the longitudinal direction and discontinuously in the lateral direction. Thus, the adhesive forms a plurality of adhesive lines that are continuous, for example, in the longitudinal direction. Of course, the width of the adhesive lines and their lateral spacing may be varied.

To measure the properties of the elastomeric material, the support layer may be separated from the elastomeric material by using, for example, acetone and/or ethyl acetate.

The elastic film may be formed of an elastic adhesive.

The elastic adhesive film may then be extruded onto and then laminated to the nonwoven web. The activated zones may extend the entire length of the nonwoven web as measured in the machine direction.

In some embodiments, the support layers are assembled by ultrasonic welding.

In the manufacture of the laminate assembly, ultrasonic welding is performed by passing the support layer between two rollers, one of which is an ultrasonic generator. One of the two rollers is an ultrasonic generator and the two rollers apply a force to the support layer perpendicular to the general plane defined by the support layer such that the support layer is laminated during ultrasonic welding.

In some embodiments, the support layer is joined by two methods selected from the following list: ultrasonic welding, high frequency welding, gluing or direct lamination (also known as thermal lamination).

In some embodiments, the plurality of projecting elements has a projecting element density greater than or equal to per cm in the resting state²3 projecting elements, preferably greater than or equal to per cm²10 projecting elements and less than or equal to per cm²400 projecting elements, preferably less than or equal to per cm²300 protruding elements.

In some embodiments, in the resting state, the plurality of projecting elements have a pattern that includes a repeating cleat pattern that extends across the width of the cleat.

The dimension of the cleats in the direction MD is greater than the dimension in the direction CD.

In some embodiments, the sum of the areas defined on the base by orthogonal projections of the protruding elements on the base is greater than or equal to 1% of the total area of the base of the cleat pattern, preferably greater than or equal to 5% of the total area of the base of the cleat pattern, and less than or equal to 60% of the total area of the base of the cleat pattern, preferably less than or equal to 40% of the total area of the base of the cleat pattern, more preferably less than or equal to 35% of the total area of the base of the cleat pattern.

In some embodiments, the thickness of the base is greater than or equal to 10 μm, preferably greater than or equal to 15 μm, and less than or equal to 200 μm, preferably less than or equal to 150 μm.

In some embodiments, the thickness of the substrate is variable.

In some embodiments, the protruding elements have a variable width.

The width of the protruding element is measured in a plane parallel to the plane XY of the base. The width of the protruding element is measured at the point of the protruding element having the largest width.

In some embodiments, the protruding elements may comprise protruding elements having different heights and/or different widths measured in a plane parallel to the plane XY.

In some embodiments, the protruding elements are pins and/or studs and/or rods, each rod having a head at an end of the rod opposite the base.

The head is arranged at an end of the protruding element opposite the base, in particular at an upper surface of the base.

"Pin" refers to a shape having no head or overhang and a maximum height greater than or equal to a maximum width. "stud (stud)" means a shape having a maximum height less than a maximum width. The pin, stud or rod has a portion of constant cross-section or a portion of reduced cross-section, the reduction facing away from the base.

In some embodiments, the height of the protruding element in a direction perpendicular to the base is greater than or equal to 0.05mm (millimeter), preferably greater than or equal to 0.10mm, and less than or equal to 0.80mm, preferably less than or equal to 0.50 mm.

In some embodiments, the width of the cleats in the resting state is greater than or equal to 5%, preferably greater than or equal to 10%, and less than or equal to 45%, preferably less than or equal to 30% of the total width of the laminate assembly.

These values are suitable, for example, for infant or child diapers or adult incontinence diaper applications.

In some embodiments, in the rest condition, the width of the cleats is comprised between 25% and 75% of the total width of the laminate assembly.

These values are suitable, for example, for absorbent article applications, such as infant or child diapers or adult incontinence diapers or feminine hygiene articles. These values can be measured once the absorbent article is assembled.

In some embodiments, in the rest condition, the width of the cleats is comprised between 55% and 100% of the total width of the laminate assembly.

These values are for example suitable for absorbent article applications, such as feminine hygiene articles. These values can be measured once the absorbent article is assembled.

In some embodiments, the support layer penetrates at least partially into the base of the cleat, for example the support layer is bonded to the cleat by direct lamination.

In some embodiments, the cleats are bonded to the support layer.

In some embodiments, the cleats are welded to the support layer by ultrasonic welding.

In some embodiments, the cleats and the elastic membrane are made of the same elastomeric material.

In some embodiments, the cleats and the elastic membrane are made of different elastomeric materials.

In some embodiments, the nonwoven web is activated before and/or after being combined with the elastic film.

In some embodiments, the base of the cleat may include two edges along the longitudinal direction, one of the edges having a peak and a valley, wherein a maximum deviation between the peak and the valley along a lateral direction orthogonal to the longitudinal direction is less than 1mm compared to a length along the longitudinal direction corresponding to three consecutive peaks.

In some embodiments, the edge has a portion of circular shape when viewed in cross-section along the longitudinal direction.

In some embodiments, the maximum distance between a peak and a valley in a lateral direction orthogonal to the longitudinal direction and over the length in the longitudinal direction corresponding to three consecutive peaks is comprised between 0.001mm and 1mm, more particularly between 0.001mm and 0.5mm, even more particularly between 0.001mm and 0.1 mm.

In some embodiments, the three consecutive peaks are smaller than the distance corresponding to the 15 steps of the protruding element, preferably smaller than the distance of 25 mm.

In some embodiments, the width of the base is greater than or equal to 1mm, preferably greater than or equal to 3mm, even more preferably greater than or equal to 5mm, and less than or equal to 500mm, preferably less than or equal to 250mm, even more preferably less than or equal to 100 mm.

In some embodiments, the stem of the protruding element is rotationally symmetric about an axis perpendicular to the upper surface of the base.

In some embodiments, the protruding elements have an asymmetric geometry with respect to a direction transverse to the longitudinal direction of the base.

In some embodiments, the protruding element is symmetrical with respect to a plane extending in the longitudinal direction of the base and passing through the axis of the stem of the protruding element.

In some embodiments, the support layer is comprised of a first nonwoven web and a second nonwoven web.

In some embodiments, the first nonwoven web and the second nonwoven web have the same properties.

In some embodiments, the first nonwoven web and the second nonwoven web are different in nature.

In some embodiments, the first nonwoven web and the second nonwoven web each comprise an inactivated zone 3 and a zone that is activated prior to assembly.

The cleats may be bonded and/or ultrasonically welded to the upper surface of the support layer. The cleats may also be engaged by directly laminating the cleats to cause the support layer to penetrate at least partially into the base before fully curing the base of the cleats.

In case the support layer is a set of thermally consolidated fibers and/or filaments, the bonding to the base is also achieved by penetration into the base of some of the fibers and/or filaments of the support layer.

If the support layer is a nonwoven web, then even if a weight of less than 80g/m is used²(material mass of nonwoven, in grams per square meter) the protruding elements can also be easily removed from the mold. For example, the weight of the nonwoven may be included at 5g/m²And 120g/m²Or at 25g/m²And 100g/m²Or between 10g/m²And 70g/m²In the meantime.

A particular advantage of this method of joining the supporting layer to the base comprising the projecting elements is that it does not cause deformation of the base, thus advantageously making it possible to maintain the shape of the base obtained during the injection-moulding step, and in particular to maintain the straight edges obtainable by the method and apparatus described below.

The present disclosure also relates to an absorbent article, in particular a disposable diaper, comprising a laminate assembly as defined above.

In some embodiments, the cleats of the laminate assembly are disposed on elastic ears of the absorbent article and/or inelastic ears of the absorbent article, the inelastic ears comprising, for example, a nonwoven.

In some embodiments, the cleats of the laminate assembly are disposed on elastic portions (such as elastic ears) of the absorbent article such that the projecting elements of the cleats extend toward the absorbent portion of the absorbent article.

In some embodiments, the cleats of the laminate assembly are disposed on the inelastic portions (e.g., inelastic ears) of the absorbent article such that the projecting elements of the cleats extend away from the absorbent portion of the absorbent article.

The present disclosure also relates to a method for manufacturing a laminated assembly, the method comprising the steps of:

-forming a cleat by dispensing elastomeric material in a forming device, the cleat comprising a base and a plurality of projecting elements extending from the base;

-assembling the support layer and the cleats by laminating the support layer and the cleats.

Direction MD refers to the machine direction and to the direction of travel of the support layer in the machine during the manufacture of the laminate assembly, direction CD refers to the cross direction and to the direction perpendicular to direction MD.

In some embodiments, the forming means may comprise a forming strip, the thickness of which is comprised between 100 μm (micrometer) and 500 μm.

In some embodiments, the assembly of the support layer and the cleat is performed before the base of the cleat is fully cured, such that the support layer penetrates at least partially into the base.

In some embodiments, the support layer may comprise a nonwoven web, and dispensing the elastomeric material through the nonwoven web in the forming device is accomplished.

In some embodiments, the assembly of the support layer and the cleats is performed by gluing.

In some embodiments, the assembly of the support layer and the cleats is performed by ultrasonic welding.

In some embodiments, the support layer may comprise an elastic membrane formed by dispensing an elastomeric material in a molding apparatus.

In some embodiments, the support layer may include an elastic film and at least one nonwoven fabric, the cleats being joined to the support layer by at least one nonwoven fabric layer.

In some embodiments, the support layer may include a nonwoven web and an elastic film, the elastic film being woven by dispensing an elastomeric material in a forming device, and the assembly of the nonwoven web being performed prior to the elastic film being fully cured to cause the nonwoven web to at least partially penetrate into the elastic film.

In some embodiments, the elastomeric material of the resilient membrane is dispensed in a molding device after the elastomeric material of the cleats has been dispensed.

In some embodiments, the cleats and the elastic membrane are made of the same elastomeric material.

In some embodiments, the support layer may comprise a second nonwoven web, the assembly of the second nonwoven web being performed prior to the elastic film being fully cured to cause the second nonwoven web to at least partially penetrate into the elastic film.

In some embodiments, the support layer may comprise a second nonwoven web, the assembly of the second nonwoven web being achieved by bonding and/or ultrasonically welding the second nonwoven web to the elastic film.

In some embodiments, the forming device may include a forming bar on which the cleats are formed and a rotational drive device.

In some embodiments, the forming device may comprise a device for forming the heads of the protruding elements, including a drive roller and a forming roller.

In some embodiments, the drive roller and the forming roller rotate at different speeds such that the heads of the projecting elements are asymmetric.

In some embodiments, the ratio of the speed of the drive roller to the speed of the forming roller is greater than or equal to 0.4, preferably greater than or equal to 0.65, and less than or equal to 1.6, preferably less than or equal to 1.35.

In some embodiments, the ratio of the speed of the drive roller to the speed of the forming roller is greater than or equal to 0.4, preferably greater than or equal to 0.65, and strictly less than 1.

In some embodiments, the ratio of the speed of the drive roller to the speed of the forming roller is equal to 1.

In some embodiments, the drive roller and the forming roller rotate at equal speeds such that the heads of the protruding elements are symmetrical and flat.

Drawings

Further features and advantages of the subject matter of the present disclosure will become apparent from the following description of embodiments, given by way of non-limiting example, with reference to the accompanying drawings, in which:

figure 1 is a schematic view of a diaper;

figure 2A is a schematic cross-sectional view according to plane II-II of figure 1 of a laminate assembly according to a first embodiment;

figure 2B is a schematic cross-sectional exploded view of the support layer;

figures 3 to 5 are schematic cross-sectional views of a lamination assembly according to other embodiments;

fig. 6 is a schematic cross-sectional view of the cleat;

figure 7 is a partially schematic cross-sectional view of a laminate assembly according to other embodiments;

fig. 8A-8F are schematic cross-sectional and top views of different embodiments of the cleats;

figure 9 is a partial schematic view of the top of the forming bar;

figures 10 and 11 are schematic cross-sectional views of the shaped bar in figure 9;

FIG. 12 is an enlarged schematic view of the pattern of the area XII of the profiled strip in FIG. 9;

figure 13 is a schematic view of a pattern of elements of a profiled bar according to other embodiments;

FIG. 14 is a schematic cross-section according to plane XIV-XIV of the profiled bar in FIG. 13;

15-18 are schematic views of a pattern of shaped bars according to other embodiments;

figure 19 shows a partial schematic cross-section according to plane XIX-XIX of the shaped bar, to form the pattern of figure 18;

fig. 20 is a schematic view of an example of a device for manufacturing cleats;

figures 21 to 23 are schematic views of an example of a plant for manufacturing laminated assemblies;

figures 24A-24C are schematic views of a lamination assembly;

FIG. 25 is a schematic view of a test sample;

figure 26 is a schematic view of an apparatus for performing elongation at break and/or deformation measurements;

fig. 27 is a graph showing the elongation at break curves of a laminate assembly comprising cleats and a laminate assembly without such cleats;

fig. 28 is a schematic view of an example of an apparatus for manufacturing cleats comprising forming means;

fig. 29 is a top view of the cleat, showing the edge characteristics of the bar.

Common elements are identified by the same numerical reference numerals throughout the drawings.

Detailed Description

Fig. 1 is a highly schematic view of a diaper 10, such as a disposable diaper. The diaper 10 is comprised of an absorbent core 12, a front waistband 14 having two front ears 16 and a back waistband 18 having two back ears 20 for attaching the diaper 10 to a wearer of the diaper. Each back ear 20 is typically provided with a retaining means 22, for example with a hook, which cooperates with an application area 24 arranged on the front waistband 14. In the hygiene field, this application area 24 is commonly referred to as a "landing area", or "comfort zone" in french.

Fig. 2A shows a first embodiment of a laminate assembly 30 that may be used to make the front ears 16 and/or back ears 20 of the diaper 10.

Hereinafter, the term laminate assembly will refer to both an uncut laminate assembly and a laminate assembly that is cut into the front ears 16 and/or back ears 20 of the diaper 10.

The laminate assembly 30 is shown in fig. 2A in a sectional view according to section II-II of fig. 1.

The laminate assembly 30 extends in a longitudinal direction X and a lateral direction Y orthogonal to the longitudinal direction X. The cross-sectional view of fig. 2A is in a cross-section YZ, the transverse direction Z being orthogonal to the plane XY and defining the thickness direction of the laminate assembly 30. The directions XYZ are orthogonal to each other.

The laminate assembly 30 in fig. 2A is comprised of a support layer 32 and cleats 34. The support layer 32 and cleats 34 extend in a longitudinal direction X and a lateral direction Y. The laminate assembly 30 is comprised of an upper surface 30A and a lower surface 30B.

In the embodiment shown in fig. 2A, the support layer 32 is comprised of a first nonwoven web 36, a second nonwoven web 38, and an elastic film 40 that are joined to one another with an adhesive 42. The elastic film 40 is joined between the first nonwoven web 36 and the second nonwoven web 38 by laminating the first nonwoven web 36, the second nonwoven web 38, the elastic film 40, and the adhesive 42.

As shown in fig. 6, the cleat 34 includes a base 34A and a plurality of projecting elements 34B. The base 34A has an upper surface 34AA and a lower surface 34AB, and the protruding elements 34B extend from the base 34A (particularly from the upper surface 34AA of the base 34A). In the lateral direction Y, the base 34A has a width L34A, and the protruding element 34B has a width L34B. The width L34B of the protruding elements 34B, measured in the lateral direction Y between two lines parallel to the longitudinal direction X and to the edges of the base 34A, includes all the protruding elements 34B tangent to the protruding elements 34B. In the embodiment of fig. 6, the width L34A of the base portion 34A is greater than the width L34B of the projecting element 34B, i.e., the width L34B of the projecting element 34B is less than or equal to the width L34A of the base portion 34A.

The projecting elements 34B project from the upper surface 30A of the laminate assembly 30.

The projecting elements 34B can form a cleat pattern 44 on the cleat 34 (i.e., the base 34A, and particularly the upper surface 34AA of the base 34A), can have an area 46 without the projecting elements 34B and an area of the cleat 34, with the projecting elements 34B forming the cleat pattern 44. The cleat pattern 44 may be singular or may repeat multiple times on the cleat 34 in the longitudinal direction X and/or the lateral direction Y. The cleat pattern 44 may include a closed profile.

Base 34A has a thickness E34A in transverse direction Z, and protruding element 34B has a height H34B in transverse direction Z. The height H34B of the projecting element 34B is perpendicular to the upper surface 34AA of the base, measured between the base and the point at which the projecting element 34B is furthest from the upper surface 34AA of the base 34A.

The plurality of projecting elements 34B may include projecting elements 34B having different heights H34B and/or different widths L34BB measured in a plane parallel to the plane XY. The width L34BB is measured at the location where the protruding element has the greatest width.

The protruding elements 34B may be pins and/or studs and/or rods, each rod having a head arranged at the end of the rod opposite the base 34A. For a given cleat 30, the projecting elements 34B may be of a single type, or may be a mixture of one or more types of projecting elements 34B.

As shown in fig. 7, the cleats 34 include pins 34BB having a height H34B in the transverse direction Z and a width L34BB in a plane parallel to the plane XY. In fig. 7, only one pin 34BB is shown. The height H34B of pin 34BB is greater than or equal to the width L34 BB. When height H34B is less than width L34BB, it is referred to as a pin. The cleats 34 are laminated with a support layer 32, which in this embodiment is formed of a nonwoven web having a portion of the fibers that have penetrated the base 34A of the cleat. Thus, it is understood that the assembly of the support layer 32 and the cleats 34 has been performed before the base 34A of the cleats 34 is fully cured, resulting in at least partial penetration of the support layer 32 into the base 34A. As shown in fig. 7, the cleats 34 and the support layer 32 comprising a nonwoven web are shown. Such nonwoven webs may form the front ears 16 and/or the back ears 20 of the diaper 10, and in particular, the cleats 34 may be disposed on the front ears 16 such that the protruding elements extend toward and/or away from the absorbent portion of the absorbent article.

In fig. 20 to 23 are shown projecting elements comprising a stem surmounted by a head.

Fig. 2B is an exploded view of two support layers 32 according to fig. 2A and shows a possible way of joining the support layers 32. In fig. 2B, two support layers 32 are shown bonded together. To form the support layer 32, after the nonwoven web, the elastic film and adhesive film have been laminated together, and the entire fig. 2B is cut in the middle to form two support layers 32.

In the embodiment shown in fig. 2B, the support layer 32 is comprised of a first nonwoven web 36 and a second nonwoven web 38. The first nonwoven web 36 and the second nonwoven web 38 may have the same or different properties.

In the embodiment shown in fig. 2B, the first nonwoven web 36 and the second nonwoven web 38 both include an inactivated region 36A, 38A and an activated region 36B, 38B prior to assembly.

In the embodiment shown in fig. 2B, the activated regions 36B, 38B are equal in size along the lateral direction Y. They may differ from one web to another and/or within the same web. The first nonwoven web 36 and the second nonwoven web 38 may also be free of activated areas due to the activation of the support layer achieved after bonding with the elastic film 40.

An adhesive 42 is applied to the first nonwoven web 36 and the second nonwoven web 38. The adhesive 42 is disposed in a solid strip 42A and in a thin line 42B. The adhesive 42 thus forms a plurality of adhesive lines 42B that are continuous in the longitudinal direction X, for example. The elastic film 40 has a width L40. The width L34A of the base 34A of the cleat 34 is less than the width L40 of the elastic membrane 40. In the example in fig. 2A, the width L34A of the base 34A of the cleat 34 corresponds to 25% of the width L40 of the elastic film 40.

The cleats 34 may be bonded and/or ultrasonically welded to the upper surface 30A of the support layer 32. The cleats 34 may also be engaged by laminating the cleats 34 prior to fully curing the base 34A of the cleats 34 to cause the support layer 32 to at least partially penetrate into the base 34A, and the second nonwoven web 38 in the manner shown in fig. 2A.

Cleats 34 may be manufactured, for example, using apparatus 100 as shown in fig. 20. The apparatus 100 allows for the manufacture of cleats 34 for the laminate assembly 30. The cleats 34 include a continuous base 34A and a plurality of projecting elements 34B. In the embodiment of fig. 20, each projecting element 34B comprises a stem 48 surmounted by a head 50. The head 50 is disposed at an end of the protruding element 34B opposite the base 34A, particularly at the upper surface 34AA of the base 34A.

The apparatus 100 as shown comprises a forming bar 102 on a rotary drive 104 comprising two rollers 104A, 104B, a material dispensing device 106 (e.g. a syringe) adapted to perform injection molding of an elastomeric molding material.

Thus, the assembly formed by the forming bar 102 and the rotary drive 104 forms a forming device.

The illustrated example including two rollers 104A, 104B is not exhaustive, and the number and arrangement of rollers may be particularly varied to accommodate different positions of the apparatus and the length of the forming bar 102. For example, three rollers may be used, or even a single roller may be used, such that the profiled beads are arranged on the periphery of the single roller, such as the profiled beads forming a sleeve. In particular, only one of the two rollers may be driven in rotation by electric means, for example roller 104A, the other roller 104B being free, i.e. without electric means, and being driven in rotation via the forming strip, itself driven by roller 104A. The direction of travel of the profile strip defines the direction MD of the cleats.

The molding bar 102 as shown includes an inner surface 102A and an outer surface 102B, the inner surface 102A being in contact with the rotary drive 104.

The material dispensing device 106 is arranged to inject molding material onto the outer surface 102B of the molding bar 102.

Specifically, the material distribution device 106 is disposed opposite the molding bar 102, spaced from the molding bar 102 to define an air gap e shown in fig. 20, wherein the boundary of the material injected onto the outer surface 102B of the molding bar 102 is designated by reference character a, corresponding to the trailing edge of the material injected into the molding bar 102 relative to the direction of travel of the molding bar 102.

The profile strip 102 is provided with a plurality of cavities 102C, allowing the realization of the projecting elements 34B of the cleats 34.

The cavities 102C are each formed to define: a stem 102C1 extending from the outer surface 102B to the inner surface 102A of the profile strip 102; and a head 102C2 extending between the stem 102C1 and the inner surface 102A of the molding bar 102.

In the example shown, the head 50 of the cavity 102C opens onto the inner surface 102A of the profile strip 102. Thus, the cavity 102C is through. The cavity 102C may also be blind, i.e., the cavity does not open from the inner surface 102A of the molding bar 102, and/or the cavity 102C may have only one stud or pin.

The portion of the cavity 102C forming the stem 102C1 extends generally in a direction perpendicular to the outer surface 102B of the molding bar 102. The portion of the cavity 102C forming the stem 102C1 generally has a rotational geometry about an axis perpendicular to the outer surface 102B of the profile strip 102 or a geometry having a plane of symmetry extending in a direction parallel to the direction of travel of the profile strip 102 and/or in a direction perpendicular to the direction of travel of the profile strip 102.

The portion of the cavity 102C forming the head 102C2 extends generally radially or transversely with respect to an axis perpendicular to the outer surface 102B of the molding bar 102, and may be rotationally symmetric about the axis perpendicular to the outer surface 102B of the molding bar 102. The portion of the cavity 102C forming the head 102C2 generally has a substantially frustoconical or hexahedral shape.

The portion of the cavity 102C forming the head 102C2 may be linear or curved, for example, to form a curved portion toward the inner surface 102A of the profile strip 102 or toward the outer surface 102B of the profile strip, the curved portion extending from the portion of the cavity 102C forming the stem 102C 1.

The portion of the cavity 102C forming the head 102C2 may have a constant or variable thickness.

In the example shown in the figures, the portion of the cavity 102C forming the head 102C2 extends radially around the portion of the cavity 102C forming the stem 102C1 and is generally disc-shaped.

The profile strip 102 may have a specific texture, such as grooves, a pattern of grooves or vent holes or pins, on its inner surface 102A or on its outer surface 102B, or may be substantially smooth, for example as described in application WO2017187103, which is incorporated by reference.

The forming strip 102 may be formed by laminating a plurality of strips and is therefore not necessarily a single piece or material.

The material dispensing device 106 is typically arranged to perform injection molding of molding material into the molding strip 102 at a section of the molding strip 102, wherein the molding strip is supported on a drive roller, in this case drive roller 104A in the example shown in fig. 20 and/or 21. The drive roller then forms the bottom of the cavity 102C.

Where injection of molding material is performed while molding bar 102 is not supported on a drive roller, then material dispensing device 106 may include a base disposed on the other side of molding bar 102 such that when injection of material is performed, inner surface 102A of molding bar 102 is supported on the base, which then forms the bottom of cavity 102C of molding bar 102.

The use of the molding bar 102 in combination with the drive device 104 is advantageous for a number of reasons, as compared to the use of conventional molding devices, such as rollers, in which the molding cavities are formed directly.

The use of profiled strips 102 is of particular interest in terms of modularity. In fact, the forming strip can be easily removed from the drive and replaced, unlike large rolls, the operations of disassembly and reassembly are particularly complex to perform. This advantage is particularly evident when the two rollers 104A, 104B are fixed to the frame on the same side, leaving the ends of the other side free to introduce/remove the forming strip. Means for guiding the profile strip may also be used to facilitate insertion and/or removal of the profile strip. The guiding means may comprise a tensioning element for the profiled strip.

Furthermore, the production of the profiled strip is greatly simplified compared to the production of a roll with profiled cavities. In fact, such rollers are generally made by stacking successive sheets, thus requiring a plurality of machining operations, and resulting in considerable constraints during assembly and each time the reference of the projecting element is changed, and are of high mass, requiring the rollers to be held by their two ends, thus complicating their replacement.

Where it is desired to form the projecting element 34B, the cavity 102C in the profile 102 may be fabricated by an etching process or by using a laser. It is also contemplated to manufacture a molding bar 102 having cavities 102C evenly distributed throughout the molding bar 102 and then filling the cavities 102C in the areas 20 where it is desired to form the protrusions 34B free. It is possible to use, for example, a profiled strip made of nickel or stainless steel or non-stainless steel.

The separation between the cleats 34 and the molding strip 102 is marked by reference character C in fig. 20, for example where the base 34A of the cleats 34 no longer contacts the molding strip 102. It may be assumed that the profile strip 102 is loaded onto the release roller 108, i.e. the release roller 106 forms a lever in the profile strip 102 to facilitate release of the protruding elements from the mould.

In the example shown, the cavity 102C of the molding strip 102 is through-penetrating. The apparatus may then include an element, such as a scraper 110, positioned to scrape the inner surface 102A of the molding bar 102 to remove excess molding material if necessary. Injection molding refers to the act of shaping a molten molding material, such as dispensing, feeding, molding, injecting, extruding.

The cleats 34 may thus be formed by: elastomeric material is dispensed into cavity 102C of molding bar 102 and against outer surface 102B of molding bar 102 by material dispensing device 106. The forming bar 102 of fig. 20 has cavities 102C, each cavity being formed to define: a stem 102C1 extending from the outer surface 102B to the inner surface 102A of the profile strip 102; and a head 102C2 extending between the stem 102C1 and the inner surface 102A of the molding bar 102. The molding bar 102 may include cavities 102 that do not have a portion defining the head 102C 2. The cavity 102C of the profile strip 102 may also be a non-through cavity and, thus, not open to the inner surface 102A of the profile strip 102.

In fig. 28 is shown a protruding element comprising a rod surmounted by a head. These protruded elements are obtained by calendering the protruded elements shown in fig. 20-23 with a forming apparatus 120 comprising a drive roll 122 and a forming roll 124.

When a symmetrical and flat head 50 is desired, the drive roller 122 and the forming roller 124 are at the same speed.

When forming the symmetrical head 50, the speeds of the drive roller 122 and the forming roller 124 are different. In particular, a ratio V122/V124 may be used, where a is greater than or equal to 0.4, preferably greater than or equal to 0.65, and less than or equal to 1.6, preferably less than or equal to 1.35.

An example of a cleat 34 is shown in fig. 8A-8F. It can be seen that not all of the projecting elements 34B have a uniform height H34B and may have different widths L34BB (see in particular the embodiment of fig. 8E). It can also be seen that the projecting elements 34B generally form a cleat pattern 44 that repeats in the longitudinal direction X (see fig. 8A-8F). The cleat pattern extends across the entire width L34A of the base 34A of the cleat 34 (i.e., the dimension of the cleat in the lateral direction Y or direction CD). However, as shown in fig. 8F, the cleats 34 may also have no repeating pattern and be formed of a single cleat pattern. The projecting elements 34B may form a cleat pattern 44 having a closed profile 44A. The protruding elements 34B may have different densities along the longitudinal direction X and the lateral direction Y and/or along the longitudinal direction X and/or the lateral direction Y.

The support layer 32 may then be engaged with the cleats 34 by adhesive, ultrasonic welding, and/or by melting the base 34A or the support layer 32.

The apparatus and associated processes set forth above may also have means and steps for assembling the support layer 32 to the base 34A.

In order to perform the assembly of the supporting layer 32 to the base 34A of the cleats 34, the proposed device 100 may comprise means for driving the supporting layer 32, which are adapted to perform the feeding of the strip and the abutment of the supporting layer 32 against the underside 34AB of the base 12 downstream of the material dispensing means 106.

Fig. 21 and 22 schematically show examples of devices 100 comprising such means. Fig. 22 is a detailed view of region XXII of fig. 21.

The apparatus shown is similar to that previously described with reference to figure 20; therefore, common elements will not be described in detail herein.

As can be seen in fig. 21 and 22, the apparatus as shown comprises a web drive 112, here consisting of two rollers 112A, 112B, configured to provide a supply of the support layer 32 downstream of the material dispensing means 106. In this embodiment, the direction MD of the cleats 34 merges with the direction MD of the support layer 32.

The support layer 32 is typically a nonwoven layer, a thermoplastic film, an elastomeric film, or a composite film, or an assembly of thermally consolidated fibers and/or filaments.

In the example shown in fig. 21 and 22, the support layer 32 is shown as a nonwoven web.

The drive means 112 of the support layer 32 are configured to feed the support layer 32 to the apparatus and to apply this support layer 32 on the lower surface 34AB of the base 34 downstream of the material dispensing means 106.

The drive 112 is configured so that the application is performed before the base 34A is fully cured. Thus, the application causes the support layer 32 to at least partially penetrate the plane defined by the lower surface 34AB of the base 34. The contact point between the base 34A and the support layer 32 is marked in the figure with the reference B.

More precisely, the lower surface 34AB of the base 34 is substantially flat and defines a plane. Applying the support layer 32 on this lower surface 34AB causes portions of the support layer 32 (e.g., fibers and/or filaments of a nonwoven web in the case where the support layer 32 is a nonwoven web) to penetrate into the base 34A, thereby penetrating the lower surface 34AB of the base 34A.

Since this application is performed before the base 34A is fully cured, there is no need to heat the base 34A and/or the support layer 32 in order to achieve this bonding.

For example, considering a base 34A made of VISTAMAXX 7050FLX (available from ExxonMobil Chemical, Houston, Tex.), typically, the substrate is applied to the lower surface 34AB of the base 34A when the temperature of the lower surface 34AB of the base 34A is included between the melting temperature of the material and the softening temperature Vicat B of the constituent material minus 30 ℃, or between the melting temperature of the constituent material and the softening temperature Vicat a of the constituent material. More particularly, when the base comprises a polyolefin-based material, the lower surface 34AB of the base 34A has a temperature comprised between 150 ℃ and 200 ℃, typically of the order of 175 ℃, which is generally measured by: infrared or laser cameras. The VICAT softening temperature is defined as the temperature obtained according to one of the methods described in standard ISO 306 or ASTM D1525, the heating rate being 50 ℃/h, the standard load of VICAT B being 50N and the standard load of VICAT a being 10N.

The support layer 32 may be applied uniformly or non-uniformly on the lower surface 34AB of the base 34A.

The bond between support layer 32 and base 34A may be uniform or non-uniform.

Where the support layer 32 is a thermally consolidated set of fibers and/or filaments, bonding to the base 34A is achieved by penetrating the fibers and/or filaments of the support layer 32 into the base 34A.

If the support layer 32 is a nonwoven web, then even if a weight of less than 80g/m is used²(material mass of nonwoven, in grams per square meter) the protruding elements can also be easily removed from the mold. For example, the weight of the nonwoven may be included at 5g/m²And 120g/m²Or at 25g/m²And 100g/m²Or between 10g/m²And 70g/m²In the meantime.

This method of joining the supporting layer 32 to the base 34A comprising the projecting elements 34B is particularly advantageous, since it does not cause the base 34A to deform, and therefore it is advantageously possible to maintain the shape of the base 34A obtained during the injection-moulding step, in particular to maintain the straight edges that can be obtained by the method and apparatus described above.

In the case where the support layer 32 is a nonwoven web, the apparatus may comprise calendering means upstream of the drive means 112, thus making it possible to perform a step of partial calendering or no calendering of the nonwoven web before it is applied on the base 34A.

The apparatus 100 of fig. 21 and 22 may be used to laminate the cleats 34 and the support layer 32, where the support layer 32 may include one or more nonwoven webs with or without a thermoplastic film (elastic or inelastic), such as the support layer 32 in fig. 2A for example.

The apparatus 100 of fig. 21 and 22 may also be used to engage the cleats 34 to the second nonwoven web 38 of fig. 2A, and then engage the second nonwoven web 38 and the cleats 34 to the elastic film 40 and the first nonwoven web 36 of fig. 2A.

The embodiment of fig. 3 differs from the embodiment of fig. 2A in that the cleats 34 pass through the second nonwoven web 38 with the projecting elements 34B projecting from the upper surface 30A of the laminate assembly 30.

In this embodiment, the cleats 34 are formed by distributing the elastomeric material through the second nonwoven web 38 in the cavities 102C of the forming strip 102. For the apparatus of fig. 23, the apparatus 100 includes a drive device 114 configured to provide a supply of the second nonwoven web 38 upstream of the material dispensing device 106. The cleats 34 are injected through the second nonwoven web 38 causing portions of the second nonwoven web 38 to penetrate into the base 34A. In fig. 23, the second nonwoven web 38 is shown as having a thickness that is less than the thickness shown for the first nonwoven web 36 for simplicity. The thicknesses of the first nonwoven web 36 and the second nonwoven web 38 may be similar or different depending on the application.

Since this application is performed before base 34A is fully cured, it is not necessary to heat base 34A and/or support layer 32 to achieve this bonding.

The second nonwoven web 38 and cleats 34 are then joined to the elastic film 40 and first nonwoven web 36 in fig. 3. The base material and the elastic film material may be the same or different, but are still elastomeric materials.

In the embodiment of fig. 4, the elastic membrane 40 is made of an elastomeric material. The elastomeric material of the elastic film is for example the same as the elastomeric material of the cleats, the first nonwoven web 36 and the second nonwoven web 3 being laminated to the elastic film 40 without the addition of adhesive.

Typically, the first and second nonwoven webs 36, 38 may be bonded to the elastic film 40 by applying the first nonwoven web 38 on the lower surface 34AB of the base 34A and the second nonwoven web 36 on the upper surface 34AA of the base 34A before the elastic film 40 is fully cured, thereby causing portions of the first and second nonwoven webs 36, 38 to penetrate into the base 34A.

Since this application is performed before base 34A is fully cured, it is not necessary to heat base 34A and/or support layer 32 to achieve this bonding. The material of the base and the material of the elastic membrane may be the same or different, but still be elastomeric materials. According to an alternative embodiment, not shown, the first nonwoven web may be bonded to the elastic film via an adhesive layer (continuously and/or in the form of adhesive lines, for example as shown in fig. 3).

The apparatus 100 of fig. 23 comprises drive means 112, 114, which drive means 112, 114 are configured to provide a feed of the first nonwoven web 36 downstream of the material dispensing device 106 and a feed of the second nonwoven web 38 upstream of the material dispensing device 106, respectively.

The apparatus of fig. 23 includes a second material-dispensing device disposed downstream of the material-dispensing device 106 when the elastomeric material of the cleats 34 is different from the elastomeric material of the elastic film 40 or when the film 40 is a non-elastic thermoplastic film.

In the embodiment of fig. 5, the second nonwoven web 38 is assembled by bonding the second nonwoven web to the elastic film 40 by the adhesive 42. The second nonwoven web 38 is divided into two portions, each portion being disposed on either side of the cleats 34. The material of the base and the material of the elastic membrane may be the same or different, but still be elastomeric materials. According to an alternative embodiment, not shown, the first nonwoven web may be bonded to the elastic film via an adhesive layer (continuously and/or in the form of adhesive lines, such as shown in fig. 3).

In the embodiment of fig. 2 to 4, the cleats are arranged midway along the lateral direction Y of the supporting layer 32. In the embodiment of fig. 5, the cleats are not centered.

As shown in fig. 24A-24B, the cleats 34 may be placed at different locations on the support layer 32. The cleats may be placed in any position between the positions shown in fig. 24A-24C. In fig. 24A-24C, the dimension of the cleats 34 in the direction MD is greater than the dimension in the direction CD, with the understanding that the cleats have a length in the direction MD and a width in the direction CD.

The molding bar 102 of fig. 20-23 has cavities 102C, each cavity formed to define: a stem 102C1 extending from the outer surface 102B to the inner surface 102A of the profile strip 102; and a head 102C2 extending between the stem 102C1 and the inner surface 102A of the molding bar 102. The molding bar 102 may include cavities 102 that do not have a portion defining the head 102C 2. The cavity 102C of the profile strip 102 may also be a non-through cavity and, thus, not open to the inner surface 102A of the profile strip 102.

Fig. 9-19 illustrate molding strips 102 for forming cleats 34 having various patterns.

Fig. 9 is a partial view of the molding strip 102 having a width L102 in the lateral direction Y that is greater than the width L34B of the protrusion element pattern 34B. The molding strip 102 is visible from the outer surface 102B. Fig. 10 is a cross-sectional view according to section XX of fig. 9, and fig. 11 is an enlarged view at XI of fig. 10, showing the forming cavity 102C of the forming bar 102. Fig. 12 is an enlarged view of fig. 9, showing the cavity 102C of the molding strip 102. Note that in the embodiment of fig. 9, the perforated portion of the forming bar 102 is not centered with respect to the axis of symmetry a of the forming bar 102. The perforated portion of the profiled strip 102 corresponding to the width L34B of the projecting element 34B on the base 34A of the cleat 34 may be centered on the axis of symmetry a, or even offset to the left or right in fig. 9.

For example,the cleats 34 obtained by dispensing the elastomeric material with the profiled strip 102 in fig. 9 to 12 are cleats having a width L34A, measured in the lateral direction Y, equal to 20 mm. Taking the entire width L34A of the antislip strip as an example, 22.52mm²Comprises 49 protruding elements 34B, i.e. with a density per cm²217.616 protruding elements, making up 13.40% of the total area of base 34A.

Fig. 13 is a view of the molding bar 102 similar to the view in fig. 12, and fig. 14 is a cross-sectional view along plane XIV, which is similar to the view in fig. 11 for the pattern in fig. 13. Fig. 13 shows a "flower" pattern of cavities 102C of the forming strip 102. As shown in fig. 14, cavity 102 may have a slope, here an angle a of 10 ° or less, to facilitate removal of the protruding portion from the mold.

For example, the cleats 34 obtained by dispensing the elastomeric material with the profiled strip 102 in fig. 13 and 14 are cleats having a width L34A, measured in the lateral direction Y, equal to 20 mm. Taking the entire width L34A of the antislip strip as an example, 130mm²Comprises 30 protruding elements 34B, i.e. with a density per cm²23.077 protruding elements, making up 29.05% of the total area of base 34A.

Fig. 15 to 19 are views similar to those in fig. 12, showing other patterns formed by the cavities 102C of the molding strip 102. For the pattern in fig. 18, the view of fig. 19 is similar to the view in fig. 14. As can be seen, the cavity 102C is not continuous and does not have a uniform depth. The cavity 102C has three different heights H102C1, H102C2, H102C 3.

For example, the cleats 34 obtained by dispensing the elastomeric material with the profiled strip 102 in fig. 15 are cleats having a width L34A, measured in the lateral direction Y, equal to 20 mm. Taking the entire width L34A of the antislip strip as an example, 110mm²Comprises 11 protruding elements 34B, i.e. with a density per cm²10 protruding elements, accounting for 25.15% of the total area of base 34A.

For example, the cleats 34 obtained by dispensing the elastomeric material with the profile strip 102 in fig. 16 are cleats having a width L34A, measured in the lateral direction Y, equal to 20 mm. For example, 382.78m, taking the entire width L34A of the antislip strip as an examplem²Comprises 225 protruding elements 34B, i.e. with a density per cm²58.78 protruding elements, accounting for 8.11% of the total area of base 34A.

For example, the cleats 34 obtained by dispensing the elastomeric material with the profiled strip 102 in fig. 17 are cleats having a width L34A, measured in the lateral direction Y, equal to 20 mm. Taking the entire width L34A of the antislip strip as an example, 251.66mm²Comprises 405 protruding elements 34B, i.e. with a density per cm²160.93 protruding elements, making up 9.91% of the total area of base 34A.

For example, the cleats 34 obtained by dispensing the elastomeric material with the profiled strip 102 in fig. 18 are cleats having a width L34A, measured in the lateral direction Y, equal to 20 mm. Taking the entire width L34A of the antislip strip as an example, 187.35mm²Comprises 35 protruding elements 34B, i.e. with a density per cm²18.682 protruding elements, making up 25.22% of the total area of base 34A.

As shown in fig. 29, the cleats 34 are obtained by injection molding an elastomeric material into the molding strip 102, so that the cleats 34 extend in the longitudinal direction X in fig. 29. The lateral direction Y is also shown in fig. 29. Here, the longitudinal direction X is parallel to the machine direction MD, i.e., the traveling direction of the cleat 34.

Two edges B are defined for the cleat 34, each extending along the longitudinal direction X, which define the two ends of the base 34A of the cleat 34 along a lateral direction Y orthogonal to the longitudinal direction X.

The projecting elements are generally arranged close to the edge B, for example, at a distance D from the edge B comprised between 2 pitches P and 3 pitches P of the projecting elements, generally equal to 2 pitches P or 3 pitches P, the distance D being measured along a lateral direction Y relative to the longitudinal direction X. The pitch P between two protruding elements corresponds to the distance between two protruding elements that are consecutive in the longitudinal direction. In the example shown in fig. 29, the projecting elements are arranged in columns along the longitudinal direction X, these columns being repeated identically along the lateral direction Y. The protruding elements may be arranged in a staggered or "honeycomb" arrangement, for example by displacing the protruding elements in the longitudinal direction.

As shown in fig. 29, each edge B has a series of peaks and valleys extending in the longitudinal direction L and extending in a plane parallel to the plane formed by the base 34A of the cleat 34, the peak and valley reflections reflecting slight irregularities in the distribution of the shaped molding material used for the cleat 34, it being understood that a perfectly straight edge is not industrially feasible.

The valleys are understood to be the areas of the edge B projecting inwardly from the cleat 34, while the peaks are understood to be the areas of the edge B projecting outwardly from the cleat 34.

Thus, the regularity of the edge B can be evaluated by means of these successive peaks and valleys.

The edge B has a portion of circular shape when viewed in cross-section transverse to the longitudinal direction. In particular, the circular shape is oriented laterally outward of the base 34A. The circular shape is produced when the base 34A is formed. In other words, the circular shape is not obtained by cutting.

The above-described apparatus and method make it possible to obtain the edge B of the cleats 34 such that, for a length L along the longitudinal direction L corresponding to three consecutive peaks, the maximum distance E between the peaks and the valleys along the lateral direction Y orthogonal to the longitudinal direction X is less than 3mm, or more precisely less than 2mm, or more precisely less than 1mm, or is comprised between 0.001mm and 1mm, more particularly between 0.001mm and 0.5mm, more particularly between 0.001mm and 0.1 mm.

Such a definition also applies to lengths corresponding to three consecutive valleys; the maximum distance between the peaks and the valleys in the lateral direction Y is less than 3mm, or more precisely less than 2mm, or more precisely less than 1mm, or is comprised between 0.001mm and 1mm, more particularly between 0.001mm and 0.5mm, more particularly between 0.001mm and 0.1 mm.

The 3 consecutive peaks or valleys are typically smaller than the distance corresponding to the 15 steps P of the protruding element, more preferably smaller than the distance of 25 mm.

Obtaining a "straight" edge B is advantageous because it eliminates the need for a subsequent step of making the edge straight (e.g., a cutting step), as such a straight edge is perceived by the user as an indicator of product quality.

Furthermore, the apparatus and method used make it possible to obtain such straight edges without having an extra thickness at the edges of the strip, since such extra thickness is not functionally relevant.

As can be appreciated from the above description, a straight edge is obtained by injection molding material through the material dispensing device 106. As noted above, subsequent demolding and shaping steps maintain these straight edges, so long as these steps do not result in forces being applied to the edges of the base 34A of the cleat 34. The cleats 34 obtained at the end of these various steps thus have straight edges as defined above.

In order to measure the static friction coefficient, the residual deformation and the elongation at break, measurement samples were prepared in a similar manner and according to the following method.

The laminate assembly was conditioned for 24 hours at a temperature of 23 ℃ ± 2 ℃ and a relative humidity of 50% ± 5% in a conventional atmosphere as defined in ASTM D5170.

The static friction coefficient was measured according to ASTM D1894 by moving a 200g (g) pad having an area of 63mm by 63mm on the surface of the cleat at a speed of 150mm/min (mm/min).

In the first part of the test, a sample of the laminated assembly was attached in an absolutely flat state to the rubbing stage of the test system using an adhesive tape. The types of belts that may be used to adhere the material sample to the friction table are well known to those of ordinary skill in the art and will not be described in further detail in this document.

In another part of the test, the front ear made from a spunbond nonwoven available from "TEXBOND nonwovens" under the brand ULTRATEX D1A 60X (60gsm PP (grams per square centimeter)) was located on the lower surface of the pad facing the upper surface of the laminate assembly sample, with the spunbond calendered surface facing the upper surface of the laminate assembly sample. The pad is translated over a length of at least 15mm over the sample to be tested, so that a value of the static friction coefficient can be obtained.

To measure the static coefficient of friction at 15% elongation, a sample of the laminate assembly 30 was held at 15% elongation of the cleats 34 by a double-sided adhesive. The measurement method is the same as that of the static friction coefficient in a static state.

For a sample of laminate assembly without cleats, for example a laminate assembly sold under the name "HighStretch Surefit 100" by the company "APLIX", with a static coefficient of friction in the direction MD of 0.37 and in the direction CD of 0.42 in the resting state, under the product number FM27R0140N010-AS 02N.

For a laminate assembly comprising a High Stretch Surefit 100 support layer and a cleats obtained by means of the profiled strip 102 of fig. 9, which in the rest state has a static coefficient of friction in direction MD of 0.53 and in direction CD of 0.88, when the sample is stretched 15% in direction CD, it has a static coefficient of friction in direction MD of 0.73 and in direction CD of 0.99.

For a laminate assembly comprising a High Stretch Surefit 100 support layer and a cleats obtained by means of the profiled strip 102 of fig. 13, which in the rest state has a static coefficient of friction in direction MD of 0.71 and in direction CD of 1.06, when the sample is stretched 15% in direction CD, it has a static coefficient of friction in direction MD of 0.57 and in direction CD of 1.07.

For a laminate assembly comprising a High Stretch Surefit 100 support layer and a cleats obtained by means of the profiled strip 102 of fig. 15, which in the rest state has a static coefficient of friction in direction MD of 0.54 and in direction CD of 0.72, when the sample is stretched 15% in direction CD, it has a static coefficient of friction in direction MD of 0.79 and in direction CD of 0.84.

For measuring the residual deformation and elongation at break, the measuring device is a dynamometer according to EN 10002, for example Synergy 200H,1column available from MTS Systems corp. together with the TESTWORKS 4.04B user software.

The sample 52 is cut into the desired shape with a cutter or scissors, see fig. 25. Sample 52 has the general shape of an isosceles trapezoid.

The cleats 34 have a length and a width. Sample 52 has a dimension in the direction CD of 80mm when the length of the cleats is parallel to the direction MD. The minor and major bases of the isosceles trapezoids are parallel to the direction MD and measure 50mm and 84mm respectively, as shown in fig. 25.

Each edge of the sample 52 was reinforced by a stiffener attached to the sample with a double-sided adhesive. Each reinforced edge of the sample 52 is then placed in the jaws 202, 204 of the load cell 200 (see figure 26). The distance between the two jaws 202, 204 was 40mm before testing.

The elongation at break test is performed at a constant speed of movement of the jaws 202, 204 relative to each other. Typically, one jaw is fixed, here lower jaw 204, and the other jaw is movable, here upper jaw 202. To perform the elongation at break test, the movable jaw is moved at a constant speed of 508mm/min until an interruption is detected.

The elongation at break test gives an elongation at break of 10N (newtons) expressed as a percentage of the initial dimension of the sample 52 or in mm, an elongation at break expressed as a percentage of the initial dimension of the sample 52 or in mm, and a force at break expressed in N.

The elongation at break test curve is shown in fig. 27. On the graph in fig. 27, the x-axis represents the elongation in percent of the original dimension of the sample 52 and the y-axis represents the force in N. Curve 1 represents the elongation at break test of the laminate assembly comprising the cleats, and curve 2 represents the elongation at break test of the support layer of the laminate assembly of curve 1 (i.e., the laminate assembly without the cleats). It can be seen that the elongation at break of curves 1 and 2 are substantially similar. On the other hand, when the support layer includes cleats, the force required to achieve breaking of sample 52 is greater. For any elongation before the maximum force, the force achieved by the laminate assembly including the cleats is greater than the force achieved by the laminate assembly without the cleats.

The residual deformation test was performed on the same equipment with the same type of sample as sample 52 tested for elongation at break.

The moving jaws have a constant speed of 508mm/min, the initial jaw distance is 40mm, and the sample is stretched until a force of 10N is reached. Once a force of 10N is reached, the movement of the movable jaw is stopped and the gap is maintained for 30 seconds. The jaws are then moved to their starting position at a constant speed and the sample 52 is held in that position for 60 seconds.

The result is a curve that gives the tensile force in N as a function of the elongation in% of the original sample size. The curve has hysteresis, and the residual deformation or SET deformation at the end of the cycle is determined as follows: SET-the intersection with the x-axis of the curve measured during the movement of the movable jaw when the movable jaw returns to its starting position (i.e. the jaw spacing is 40 mm).

While the present disclosure has been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these examples without departing from the general scope of the invention as defined by the claims. Furthermore, individual features of the different embodiments mentioned may be combined in further embodiments. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. For example, the cleats may have a direction MD that is non-parallel to the direction MD of the support layer. As an alternative to the embodiments of fig. 2A to 8F, 20 to 25 and 28, it is possible to have studs and/or pins and/or rods covered on top with a head according to fig. 20 to 23 and/or rods covered on top with a head according to fig. 28.