Patent ID: 7195729
Filing Date: 2007-03-27
Classification: A44B,B29C,B29L,B32B,Y10T

Abstract:
1. A method for producing a composite web, the method comprising: providing a forming tool comprising an exterior surface that comprises one or more depressions formed therein; delivering a molten thermoplastic composition onto the exterior surface of the forming tool; maintaining the exterior surface of the forming tool at a roll temperature that is below a melt processing temperature of the thermoplastic composition; wiping the molten thermoplastic composition on the exterior surface of the forming tool, wherein at least some of the molten thermoplastic composition enters the one or more depressions; transferring the thermoplastic composition in the one or more depressions to a substrate by contacting a first major surface of the substrate to the thermoplastic composition in the one or more depressions, wherein a portion of the thermoplastic composition in the one or more depressions that is proximate surfaces of the one or more depressions falls below the melt processing temperature of the thermoplastic composition after the depositing and before the thermoplastic composition in the one or more depressions contacts the first major surface of the substrate; and separating the substrate and the thermoplastic composition in the one or more depressions from the forming tool after the transferring, wherein a composite web is formed that comprises one or more polymeric structures of the thermoplastic composition located on the first major surface of the substrate, wherein the area occupied by at least one polymeric structure of the one or more polymeric structures comprises a bonded area in which the thermoplastic composition of the polymeric structure is attached to the first major surface of the substrate and at least one detached area in which the polymeric structure is not attached to the first major surface of the substrate.