Patent ID: 7037457
Filing Date: 2006-05-02
Classification: B29C,B29L

Abstract:
1. A method for producing a composite web, the method comprising: providing a transfer roll comprising an exterior surface that comprises one or more depressions formed therein; delivering a molten thermoplastic composition onto the exterior surface of the transfer roll; wiping the molten thermoplastic composition from the exterior surface of the transfer roll, wherein a portion of the molten thermoplastic composition enters the one or more depressions, and wherein the portion of the molten thermoplastic composition in the one or more depressions remains in the one or more depressions after wiping the molten thermoplastic composition from the exterior surface of the transfer roll, and substantially all of the one or more depressions are substantially filled with the molten thermoplastic composition after the wiping; forcing a portion of a first major surface of a substrate into the one or more depressions, wherein the first major surface comprises a porous surface comprising fibers, and wherein a portion of the molten thermoplastic composition in the one or more depressions infiltrates the porous surface, and still further wherein the molten thermoplastic composition encapsulates at least a portion of at least some of the fibers; separating the substrate from the transfer roll, wherein one or more discrete polymeric regions comprising the thermoplastic composition are located on the first major surface of the substrate after separating the substrate from the transfer roll; contacting the one or more discrete polymeric regions on the substrate with a forming tool under pressure, wherein a portion of the thermoplastic composition in at least one discrete polymeric region of the one or more discrete polymeric regions contacting the forming tool enters a plurality of cavities in the forming tool; and separating the substrate and the one or more discrete polymeric regions from the forming tool, wherein the at least one discrete polymeric region comprises a plurality of structures formed thereon after separating the one or more discrete polymeric regions from the forming tool, the plurality of structures corresponding to the plurality of cavities in the forming tool.