Patent Publication Number: US-11654668-B2

Title: Laminate sheet

Description:
PRIORITY CLAIM 
     This application is a continuation of U.S. patent application Ser. No. 16/841,733, filed Apr. 7, 2020, which is a continuation of U.S. patent application Ser. No. 16/276,825, filed Feb. 15, 2019, which is a continuation of U.S. patent application Ser. No. 15/493,240, filed Apr. 21, 2017, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/326,374, filed Apr. 22, 2016, each of which is expressly incorporated by reference herein. 
    
    
     BACKGROUND 
     The present disclosure relates to a lamination system, and particularly to a system for laminating a web to a sheet. 
     SUMMARY 
     According to the present disclosure, a lamination system includes a sheet supply, a material supply, and a laminator. The laminator causes a sheet from the sheet supply to be laminated to a web from the material supply to establish a laminated sheet. 
     In illustrative embodiments, the lamination system further includes a slitter. The slitter slits the sheet to establish strips which pass through the laminator for bonding with the web from the material supply. The material supply includes a first web and a second web. 
     In illustrative embodiments, the laminator includes a pair of lamination nip rollers and adhesive applicators. The adhesive applicators are configured to selectively apply adhesive to portions of the first and second webs. The first web passes through the lamination nip rollers along a first side of the strips and the second web passes through the lamination nip rollers along a second side of the strips opposite the first side. The first web is bonded to some of the strips and the second web is bonded to the remaining strips to form laminate sheets having alternating zones of sheet and material. 
     In illustrative embodiments, the laminator includes two lamination stations. Each lamination station includes adhesive applicators and lamination nip rollers. The first web and some of the strips pass through a first lamination station to form a first laminate sheet. The second web and the other film strips pass through a second lamination station to form a second laminate sheet. 
     In illustrative embodiments, the laminator includes alignment nip rollers and an ultrasonic welder. Kiss coaters apply an anti-bond material to portions of the first and second webs. The ultrasonic welder bonds the strips to the uncoated portions of the webs to form separate laminate sheets. 
     In illustrative embodiments, the laminator includes two lamination stations. Each lamination station includes alignment nip rollers and an ultrasonic welder. The first web and some of the strips pass through a first lamination station to form a first laminate sheet. The second web and the other strips pass through a second lamination station to form a second laminate sheet. 
     Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived. 
    
    
     
       BRIEF DESCRIPTIONS OF THE DRAWINGS 
       The detailed description particularly refers to the accompanying figures in which: 
         FIG.  1    is an upper perspective view of an in-line lamination system in accordance with the present disclosure showing that a film is slit into strips and fed through a pair of lamination nip rollers to bond with non-woven webs feeding through the same pair of lamination nip rollers and suggesting that some of the strips of film adhere to an upper non-woven web while the other strips of film adhere to a lower non-woven web such that laminate sheets are formed having alternating zones of non-woven material and film along their widths as the laminate sheets are vertically separated from one another; 
         FIG.  2    is a side elevation view of the in-line lamination system of  FIG.  1    showing that a single sheet of film is combined with two sheets of non-woven material to form two sheets of laminated material for use in subsequent processing; 
         FIG.  3    is a front elevation view of the in-line lamination system of  FIG.  1    showing the diverging laminate sheets after leaving the lamination nip rollers and suggesting that a width of the upper non-woven web (W 2 ) is larger than a combined width of the incoming strips of film (W 1 ) which is larger than a width of the lower non-woven web (W 3 ) where an odd number of strips of film are used to form the laminate sheets; 
         FIG.  4    is a front elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing diverging laminate sheets of film and non-woven material after leaving lamination nip rollers of the in-line lamination system and suggesting that a width of an upper non-woven web (W 2 ) is equal to a width of the incoming film (W 1 ) which is equal to a width of the lower non-woven web (W 3 ) where an even number of strips of film are used to form the laminate sheets; 
         FIG.  5    is an upper perspective view of another embodiment of an in-line lamination system in accordance with the present disclosure showing that the in-line lamination system includes two lamination stations and suggesting that a single film is slit into multiple strips with some strips passing through an upper lamination station to bond with a non-woven web and form a first laminate sheet and the other strips of film passing through a lower lamination station to bond with a non-woven web and form a second laminate sheet; 
         FIG.  6    is a side elevation view of the in-line lamination system of  FIG.  5   ; 
         FIG.  7    is a side elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing that the in-line lamination system includes adhesive applicators configured to dispense adhesive on strips of film as the strips enter upper and lower pairs of lamination nip rollers to adhere with non-woven webs to form laminate sheets; 
         FIG.  8    is a side elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing a film, an upper non-woven web, and a lower non-woven web are aligned with one another to move toward lamination nip rollers for laminating; 
         FIG.  9    is a side elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing that the in-line lamination system includes a pair of alignment nip rollers configured to gather and align strips of film with upper and lower non-woven webs and an ultrasonic welder for bonding the strips of film with the non-woven webs to form separate laminate sheets and suggesting that kiss coaters apply an anti-bond material to the non-woven webs to allow zoned bonding of the non-woven webs with the film strips; 
         FIG.  10    is an upper plan view of the kiss coater of  FIG.  9    showing that the kiss coater includes a kiss roller and one or more pass-over skids and suggesting that the kiss roller gathers anti-bond material for application on the non-woven web as the non-woven web passes over the kiss roller and that the skids block application of the anti-bond material to portions of the non-woven web; 
         FIG.  11    is a side elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing that the in-line lamination system includes two pairs of alignment nip rollers configured to gather and align strips of film with upper and lower non-woven webs and ultrasonic welders for bonding the strips of film with the non-woven webs to form separate laminate sheets; 
         FIG.  12    is a diagrammatic view of the in-line lamination system of  FIG.  1    showing that the in-line lamination system includes a film supply, an optional breathable film activation station, an optional elastic film activation station, an optional printer for printing on the film, a film slitter, and a laminator; 
         FIG.  13    is a view similar to  FIG.  12    showing one embodiment of subsequent processing stations in the in-line lamination system including an optional laminate sheet slitter and laminate sheet roll-up station; 
         FIG.  14    is a view similar to  FIG.  13    showing another embodiment of subsequent processing stations in the in-line lamination system including a laminate sheet alignment station, a sheet lamination station for forming multiple sections of laminate product, an optional laminate product slitter to separate adjacent sections of laminate product into strips, and a laminate product roll-up station; 
         FIG.  15    is a sectional view of one laminate product formed by the in-line lamination system of  FIG.  14    showing that the laminate product includes two outer layers of non-woven material with two narrower inner layers of film; 
         FIG.  16    is a side elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing that the in-line lamination system includes a pair of lamination nip rollers configured to bond strips of film with non-woven webs feeding through the same pair of lamination nip rollers and suggesting that kiss coaters apply an anti-bond material to the non-woven webs to allow zoned bonding of the non-woven webs with the film strips; and 
         FIG.  17    is a side elevation view of another embodiment of an in-line lamination system in accordance with the present disclosure showing that the in-line lamination system includes a pair of lamination nip rollers to bond strips of film with non-woven webs feeding through the same pair of lamination nip rollers and suggesting that print heads apply an anti-bond material to the film to allow zoned bonding of the non-woven webs with the film strips. 
     
    
    
     DETAILED DESCRIPTION 
     An in-line lamination system  10  in accordance with the present disclosure is shown in  FIG.  1   . In-line lamination system  10  includes a film slitter  12  and a laminator  14 . A film  16 , such as a breathable or elastic plastic film, is delivered from a film supply, such as an extruder  62  shown in  FIG.  12   , and passes through slitter  12  to divide film  16  into strips  18 . Strips  18  pass through laminator  14  to bond with non-woven webs  13 ,  15  to form separate laminate sheets  17 ,  19  (sometimes called a bi-laminate) having alternating sections of exposed non-woven material  34  and film  36  laminated to and covering a portion of the underlying non-woven material as suggested in  FIGS.  3  and  4   . Each laminate sheet  17 ,  19  is configured to be separated into multiple strips of laminate material having a central section of film  36  and sections of non-woven material  34  extending along side edges of film section  36 . In some embodiments, film  16  is pre-processed before lamination as suggested in  FIG.  12   . In some embodiments, laminate sheets  17 ,  19  are post-processed after lamination as suggested in  FIGS.  13 - 15   . 
     In the illustrative embodiment, laminator  14  includes adhesive applicators  22  and lamination nip rollers  24  as shown in  FIGS.  1  and  2   . A non-woven material supply  26  includes supply rolls  23 ,  25  for feeding non-woven webs  13 ,  15  into lamination nip rollers  24  as suggested in  FIG.  2   . Non-woven webs or fabrics may be formed from many processes, such as, for example, meltblowing processes, spunbonding processes, hydroentangling processes, and bonded carded web processes. Film strips  18  pass through lamination nip rollers  24  such that non-woven web  13  extends along an upper side of film strips  18  and non-woven web  15  extends along a lower side of film strips  18 . 
     Adhesive applicators  22  are arranged to apply an adhesive material along portions of non-woven webs  13 ,  15  where film strips  18  are to be bonded as suggested in  FIG.  1   . In the illustrative embodiment, adhesive applicators  22  apply adhesive onto lower non-woven web  15  along two spaced apart lanes such that two film strips  18   b ,  18   d  bond with lower non-woven web  15 . Similarly, adhesive applicators  22  apply adhesive onto upper non-woven web  13  along three spaced apart lanes such that the remaining three film strips  18   a ,  18   c ,  18   e  bond with upper non-woven web  13 . 
     Lamination nip rollers  24  apply pressure to film strips  18  and non-woven webs  13 ,  15  to bond film strips  18  with the respective non-woven webs  13 ,  15  and form laminate sheets  17 ,  19  as suggested in  FIGS.  1  and  2   . In some embodiments, lamination nip rollers  24  are heated or cooled. Divider rollers  28  separate laminate sheets  17 ,  19  as suggested in  FIG.  2   . Adjacent film strips  18   a ,  18   b ,  18   c ,  18   d ,  18   e  diverge and are carried on non-woven webs  13 ,  15  as laminate sheets  17 ,  19  separate from one another as suggested in  FIG.  1   . Film strips  18   a ,  18   c ,  18   e  form part of laminate sheet  17  while film strips  18   b ,  18   d  form part of laminate sheet  19 . The distance between film slitter  12  and laminator  14  is minimized to minimize the distance traveled by film strips  18 , which may be susceptible to tearing, before being bonded with non-woven webs  13 ,  15 . Likewise, film strips  18  move in the machine direction of in-line lamination system  10  and do not experience lateral changes in direction to minimize stress on film strips  18  before lamination with non-woven webs  13 ,  15 . 
     Film strips  18  bonded to each laminate sheet  17 ,  19  are spaced apart from one another as suggested in  FIG.  3   . In a post-processing step, non-woven material  34  positioned between adjacent film strips  18  of laminate sheets  17 ,  19  is cut along slit lines  39  (shown in phantom) to separate laminate sheets  17 ,  19  into multiple strips of laminate material  32 . Each strip of laminate material  32  includes sections of non-woven material  34  positioned along opposing edges of a section of film  36 . A width of non-woven material sections  34  compared to a width of film section  36  can be varied at the selection of an operator of in-line lamination system  10 . In some embodiments, non-woven material sections  34  are each half as wide as film section  36 . In some embodiments, non-woven material sections  34  are each less than half as wide as film section  36 . In some embodiments, portions of non-woven material sections  34  are trimmed away such that non-woven material sections  34  are each less than half as wide as film section  36 . 
     In one illustrative embodiment, a width W 2  of upper non-woven web  13  is larger than a combined width W 1  of the incoming film strips  18 , and width W 1  is larger than a width W 3  of lower non-woven web  15  where an odd number of film strips  18  are used to form laminate sheets  17 ,  19  as suggested in  FIG.  3   . Center lines of non-woven webs  13 ,  15  and film  16  are aligned during lamination through laminator  14  as shown in  FIG.  3   . In another illustrative embodiment, widths W 1 , W 2 , W 3  are equal to one another when an even number of film strips  18  are used to form laminate sheets  17 ,  19  as suggested in  FIG.  4   . Center lines of non-woven webs  13 ,  15  and film  16  are misaligned during lamination through laminator  14  as shown in  FIG.  4   . The relative sizes of film  16  and non-woven webs  13 ,  15  are adjustable at the selection of an operator of in-line lamination system  10 . 
     Another embodiment of an in-line lamination system  210  in accordance with the present disclosure is shown in  FIGS.  5  and  6   . In-line lamination system  210  is similar to in-line lamination system  10  and includes a film slitter  212  and a laminator  214 . A film  216 , such as a breathable or elastic plastic film, passes through slitter  212  to divide film  216  into strips  218 . Strips  218  pass through laminator  214  to bond with non-woven webs  213 ,  215  to form separate laminate sheets  217 ,  219  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     In the illustrative embodiment, laminator  214  includes two lamination stations  242 ,  244  as shown in  FIGS.  5  and  6   . Each lamination station  242 ,  244  include adhesive applicators  222  and lamination nip rollers  224 . A non-woven material supply  226  includes supply rolls  223 ,  225  for feeding non-woven webs  213 ,  215  into lamination stations  242 ,  244 , respectively. Adjacent film strips  218  are directed to one of lamination stations  242 ,  244  in an alternating pattern such that film strips  218   a ,  218   c ,  218   e  pass through lamination station  242  to bond with non-woven web  213  while the remaining film strips  218   b ,  218   d  pass through lamination station  242  to bond with non-woven web  215  as suggested in  FIG.  5   . An idler  246  guide&#39;s film strips  218  toward lamination station  244 . 
     Adhesive applicators  222  are arranged to apply an adhesive material along portions of non-woven webs  213 ,  215  where film strips  218  are to be bonded as suggested in  FIG.  5   . In the illustrative embodiment, film strips  218   a ,  218   c ,  218   e  passing through lamination station  242  are laterally spaced apart from one another and adhesive applicators  222  apply adhesive onto upper non-woven web  213  along spaced apart lanes where film strips  218   a ,  218   c ,  218   e  are to be bonded with upper non-woven web  213 . Similarly, film strips  218   b ,  218   d  passing through lamination station  244  are laterally spaced apart from one another and adhesive applicators  222  apply adhesive onto lower non-woven web  215  along spaced apart lanes where film strips  218   b ,  218   d  are to be bonded with lower non-woven web  215 . 
     Lamination nip rollers  224  apply pressure to film strips  218  and non-woven webs  213 ,  215  to bond film strips  218  with the respective non-woven webs  213 ,  215  and form laminate sheets  217 ,  219  as suggested in  FIGS.  5  and  6   . In some embodiments, lamination nip rollers  224  are heated or cooled. The distance between film slitter  212  and laminator  214  is minimized to minimize the distance traveled by film strips  218 , which may be susceptible to tearing, before being bonded with non-woven webs  213 ,  215 . Likewise, film strips  218  move in the machine direction of in-line lamination system  210  and do not experience lateral changes in direction to minimize stress on film strips  218  before lamination with non-woven webs  213 ,  215 . Laminate sheets  217 ,  219  move through in-line lamination system  210  for roll-up or further processing at the selection of an operator. 
     Another embodiment of an in-line lamination system  310  in accordance with the present disclosure is shown in  FIG.  7   . In-line lamination system  310  is similar to in-line lamination system  210  and includes a film slitter  312  and a laminator  314 . A film  316 , such as a breathable or elastic plastic film, passes through slitter  312  to divide film  316  into strips  318 . Strips  318  pass through laminator  314  to bond with non-woven webs  313 ,  315  to form separate laminate sheets  317 ,  319  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     In the illustrative embodiment, laminator  314  includes two lamination stations  342 ,  344  as shown in  FIG.  7   . Each lamination station  342 ,  344  include adhesive applicators  322  and lamination nip rollers  324 . A non-woven material supply  326  includes supply rolls  323 ,  325  for feeding non-woven webs  313 ,  315  into lamination stations  342 ,  344 , respectively. Adjacent film strips  318  are directed to one of lamination stations  342 ,  344  in an alternating pattern such that film strips  318   a ,  318   c ,  318   e  pass through lamination station  342  to bond with non-woven web  313  while the remaining film strips  318   b ,  318   d  pass through lamination station  342  to bond with non-woven web  315 . An idler  346  guide&#39;s film strips  318  toward lamination station  344 . 
     Adhesive applicators  322  are arranged to apply an adhesive material onto film strips  318  as suggested in  FIG.  7   . Backer rolls  348  support film strips  318  as the adhesive material is applied. In the illustrative embodiment, film strips  318   a ,  318   c ,  318   e  passing through lamination station  342  are laterally spaced apart from one another during bonding with upper non-woven web  313 . Similarly, film strips  318   b ,  318   d  passing through lamination station  344  are laterally spaced apart from one another during bonding with lower non-woven web  315 . 
     Lamination nip rollers  324  apply pressure to film strips  318  and non-woven webs  313 ,  315  to bond film strips  318  with the respective non-woven webs  313 ,  315  and form laminate sheets  317 ,  319  as suggested in  FIG.  7   . In some embodiments, lamination nip rollers  324  are heated or cooled. The distance between film slitter  312  and laminator  314  is minimized to minimize the distance traveled by film strips  318 , which may be susceptible to tearing, before being bonded with non-woven webs  313 ,  315 . Likewise, film strips  318  move in the machine direction of in-line lamination system  310  and do not experience lateral changes in direction to minimize stress on film strips  318  before lamination with non-woven webs  313 ,  315 . Laminate sheets  317 ,  319  move through in-line lamination system  310  for roll-up or further processing at the selection of an operator. 
     Another embodiment of an in-line lamination system  410  in accordance with the present disclosure is shown in  FIG.  8   . In-line lamination system  410  is similar to in-line lamination system  10  and includes a film slitter  412  and a laminator  414 . A film  416 , such as a breathable or elastic plastic film, passes through slitter  412  to divide film  416  into strips  418 . Laminator  414  includes adhesive applicators  422  and lamination nip rollers  424  for bonding film strips  418  with non-woven webs  413 ,  415 . Strips  418  pass through laminator  414  to bond with the respective non-woven webs  413 ,  415  to form separate laminate sheets  417 ,  419  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     Film  416  is continuously supplied to in-line lamination system  410  using an extruder, for example. A non-woven material supply of in-line lamination system  410  is configured to continuously supply non-woven webs  413 ,  415  for lamination with film  416 . Film  416  and non-woven webs  413 ,  415  move together along a machine direction of in-line lamination system  410  toward laminator  414 . 
     Another embodiment of an in-line lamination system  510  in accordance with the present disclosure is shown in  FIG.  9   . In-line lamination system  510  is similar to in-line lamination system  10  and includes a film slitter  512  and a laminator  514 . A film  516 , such as a breathable or elastic plastic film, passes through slitter  512  to divide film  516  into strips  518 . Strips  518  pass through laminator  514  to bond with the respective non-woven webs  513 ,  515  to form separate laminate sheets  517 ,  519  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     In the illustrative embodiment, laminator  514  includes alignment nip rollers  524  and an ultrasonic welder  522  as shown in  FIG.  10   . A non-woven material supply  526  includes supply rolls  523 ,  525  for feeding non-woven webs  513 ,  515  into alignment nip rollers  524 . Film strips  518  pass through alignment nip rollers  524  such that non-woven web  513  extends along an upper side of film strips  518  and non-woven web  515  extends along a lower side of film strips  518 . 
     In the illustrative embodiment, anti-bond kiss coaters  552 ,  554  are arranged to apply an anti-bond material, such as a deadener, along portions of non-woven webs  513 ,  515  where film strips  518  are not to be bonded as suggested in  FIG.  9   . One embodiment of an anti-bond kiss coater  554  is illustrated in  FIG.  10   . Anti-bond kiss coater  554  includes a supply of anti-bond material  551 , a kiss roller  553 , and pass-over skids  555 . Kiss roller  553  distributes the anti-bond material received from supply  551  to non-woven web  515  as non-woven web  515  passes anti-bond kiss coaters  554 . Pass-over skids  555  block application of the anti-bond material along portions of non-woven web  515  where film strips  518  are to be bonded. In some embodiments, pass-over skids  555  are coated in a non-stick material, such as TEFLON. Anti-bond kiss coater  552  operates similar to anti-bond kiss coater  554  for upper non-woven web  513  as suggested in  FIG.  9   . 
     The anti-bond material forms a barrier between film strips  518  and non-woven webs  513 ,  515  to block bonding of film strips  518  along the coated portions of non-woven webs  513 ,  515  during ultrasonic welding. The coated portions of non-woven web  513  are offset from the coated portions of non-woven web  515  such that film strips  518   a ,  518   c ,  518   e  are only bonded to non-woven web  513  and the remaining film strips  518   b ,  518   d  are only bonded to non-woven web  515 . The anti-bond material applied to non-woven webs  513 ,  515  blocks film strips  518  from bonding to both non-woven webs  513 ,  515  so that separate laminate sheets  517 ,  519  can be formed. 
     In the illustrative embodiment, film strips  518  and non-woven webs  513 ,  515  all pass together through ultrasonic welder  522  for bonding as suggested in  FIG.  9   . A support roll  556  supports film strips  518  and non-woven webs  513 ,  515  during bonding. In some embodiments, support roll  556  is machined or etched with depressions to define areas of localized bonding between film strips  518  and non-woven webs  513 ,  515  as each passes through ultrasonic welder  522 . In some embodiments, material is added to film strips  518  or non-woven webs  513 ,  515  in a pattern to define areas of localized bonding between film strips  518  and non-woven webs  513 ,  515  as each passes through ultrasonic welder  522 . 
     Alignment nip rollers  524  collect film strips  518  and non-woven webs  513 ,  515  and direct each toward ultrasonic welder  522  as suggested in  FIG.  9   . The distance between film slitter  512  and laminator  514  is minimized to minimize the distance traveled by film strips  518 , which may be susceptible to tearing, before being bonded with non-woven webs  513 ,  515 . Likewise, film strips  518  move in the machine direction of in-line lamination system  510  and do not experience lateral changes in direction to minimize stress on film strips  518  before lamination with non-woven webs  513 ,  515 . Laminate sheets  517 ,  519  move through in-line lamination system  510  for roll-up or further processing at the selection of an operator. 
     Another embodiment of an in-line lamination system  610  in accordance with the present disclosure is shown in  FIG.  11   . In-line lamination system  610  is similar to in-line lamination system  510  and includes a film slitter  612  and a laminator  614 . A film  616 , such as a breathable or elastic plastic film, passes through slitter  612  to divide film  616  into strips  618 . Strips  618  pass through laminator  614  to bond with the respective non-woven webs  613 ,  615  to form separate laminate sheets  617 ,  619  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     In the illustrative embodiment, laminator  614  includes two lamination stations  642 ,  644  as shown in  FIG.  11   . Each lamination station  642 ,  644  include alignment nip rollers  624  and an ultrasonic welder  622 . A non-woven material supply  626  includes supply rolls  623 ,  625  for feeding non-woven webs  613 ,  615  into alignment nip rollers  624 . Adjacent film strips  618  are directed to one of lamination stations  642 ,  644  in an alternating pattern such that film strips  618   a ,  618   c ,  618   e  pass through lamination station  642  to bond with non-woven web  613  while the remaining film strips  618   b ,  618   d  pass through lamination station  642  to bond with non-woven web  615 . An idler  646  guide&#39;s film strips  618  toward lamination station  644 . 
     In the illustrative embodiment, film strips  618   a ,  618   c ,  618   e  passing through lamination station  642  are laterally spaced apart from one another and pass through ultrasonic welder  622  for bonding with upper non-woven web  613 . In some embodiments, ultrasonic welder  622  is zoned to apply energy along the portions where film strips  618  and non-woven web  613  overlap. Likewise, film strips  618   b ,  618   d  passing through lamination station  644  are laterally spaced apart from one another and pass through ultrasonic welder  622  for bonding with lower non-woven web  615 . In some embodiments, ultrasonic welder  622  is zoned to apply energy along the portions where film strips  618  and non-woven web  615  overlap. 
     Support rolls  656  supports film strips  618  and non-woven webs  613 ,  615  during bonding. In some embodiments, support roll  656  are machined or etched with depressions to define areas of localized bonding between film strips  618  and non-woven webs  613 ,  615  as each passes through ultrasonic welders  622 . In some embodiments, material is added to film strips  618  or non-woven webs  613 ,  615  in a pattern to define areas of localized bonding between film strips  618  and non-woven webs  613 ,  615  as each passes through ultrasonic welders  622 . 
     Alignment nip rollers  624  collect film strips  618  and non-woven webs  613 ,  615  and directs each toward ultrasonic welders  622  as suggested in  FIG.  11   . The distance between film slitter  612  and laminator  614  is minimized to minimize the distance traveled by film strips  618 , which may be susceptible to tearing, before being bonded with non-woven webs  613 ,  615 . Likewise, film strips  618  move in the machine direction of in-line lamination system  610  and do not experience lateral changes in direction to minimize stress on film strips  618  before lamination with non-woven webs  613 ,  615 . Laminate sheets  617 ,  619  move through in-line lamination system  610  for roll-up or further processing at the selection of an operator. 
     In one illustrative embodiment, in-line lamination system  10  includes a film extruder  62  for continuously forming film  16 , slitter  12 , and laminator  14  as suggested in  FIG.  12   . Film  16  can be sent through optional pre-processing steps before passing through slitter  12  and laminator  14 . An optional breathable film activation station  64  is arranged to impart breathability to film  16  through perforation or ring-roll activation for example. An optional elastic film activation station  68  is arranged to impart additional elasticity to film  16 . An optional printer  66  is arranged to print graphics or other patterns on one or both sides of film  16 . 
     In one illustrative embodiment, laminate sheets  17 ,  19  formed by in-line lamination system  10  proceed to a roll-up station  72  where laminate sheets  17 ,  19  are collected for transportation as suggested in  FIG.  13   . An optional post-processing step is to slit laminate sheets  17 ,  19  into multiple strips of laminate material in a slitting station  74  before roll-up. 
     In another illustrative embodiment, laminate sheets  17 ,  19  are formed into a laminate product  90  (sometimes called a tri-laminate) as suggested in  FIGS.  14  and  15   . Film sections  36  of upper and lower laminate sheets  17 ,  19  are aligned with one another in an alignment station  92  and laminate sheets  17 ,  19  are laminated together in a lamination station  94  along non-woven sections  34  forming multiple strips of laminate product  90 . In some embodiments, alignment station  92  includes a sheet rotator for rotating a laminate sheet so that film sections face each other, such as, for example, one of laminate sheets  217 ,  219  that both have film sections facing downward and not toward one another as suggested in  FIGS.  5  and  6   . Laminate sheets  17 ,  19  can optionally pass through a ring-roll activation station  91  separately or through a ring-roll activation station  95  after being laminated together to add elasticity to the non-woven material attached to film sections  36 . Adjacent strips of laminate product  90  are optionally separated from one another in a slitting station  96  before roll-up for transportation in a roll-up station  98 . 
     Laminate product  90  includes overlapping sections of film  36  surrounded by non-woven material as suggested in  FIG.  15   . In the illustrative embodiment, film sections  36  form a moisture barrier and the surrounding non-woven material  35  provides a soft exterior finish to laminate product  90 . Laminate product  90  is useful in hygiene applications, such as diapers and other incontinence products, and healthcare applications, such as medical gowns and drapes, for example. 
     Another embodiment of an in-line lamination system  710  in accordance with the present disclosure is shown in  FIG.  16   . In-line lamination system  710  is similar to in-line lamination system  510  and includes a film slitter  712  and a laminator  714 . A film  716 , such as a breathable or elastic plastic film, passes through slitter  712  to divide film  716  into strips  718 . Strips  718  pass through laminator  714  to bond with the respective non-woven webs  713 ,  715  to form separate laminate sheets  717 ,  719  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     In the illustrative embodiment, laminator  714  includes adhesive applicators  722  and lamination nip rollers  724  as shown in  FIG.  16   . A non-woven material supply  726  includes supply rolls  723 ,  725  for feeding non-woven webs  713 ,  715  into lamination nip rollers  724 . Film strips  518  pass through lamination nip rollers  724  such that non-woven web  713  extends along an upper side of film strips  718  and non-woven web  715  extends along a lower side of film strips  718 . 
     Adhesive applicators  722  are arranged to apply an adhesive material along both sides of film strips  718  as suggested in  FIG.  16   . In the illustrative embodiment, anti-bond kiss coaters  752 ,  754  are arranged to apply an anti-bond material, such as a deadener, along portions of non-woven webs  713 ,  715  where film strips  718  are not to be bonded. The anti-bond material forms a barrier between film strips  718  and non-woven webs  713 ,  715  to block bonding of film strips  718  along the coated portions of non-woven webs  713 ,  715 . 
     Lamination nip rollers  724  apply pressure to film strips  718  and non-woven webs  713 ,  715  to bond film strips  718  with the respective non-woven webs  713 ,  715  and form laminate sheets  717 ,  719  as suggested in  FIG.  16   . In some embodiments, lamination nip rollers  724  are heated or cooled. The anti-bond coated portions of non-woven web  713  are offset from the anti-bond coated portions of non-woven web  715  such that film strips  718   a ,  718   c ,  718   e  are only bonded to non-woven web  713  and the remaining film strips  718   b ,  718   d  are only bonded to non-woven web  715 . The anti-bond material applied to non-woven webs  713 ,  715  blocks film strips  718  from bonding to both non-woven webs  713 ,  715  so that separate laminate sheets  717 ,  719  can be formed. 
     Divider rollers  728  separate laminate sheets  717 ,  719  as suggested in  FIG.  16   . Adjacent film strips  718   a ,  718   b ,  718   c ,  718   d ,  718   e  diverge and are carried on non-woven webs  713 ,  715  as laminate sheets  717 ,  719  separate from one another. Film strips  718   a ,  718   c ,  718   e  form part of laminate sheet  717  while film strips  718   b ,  718   d  form part of laminate sheet  719 . The distance between film slitter  712  and laminator  714  is minimized to minimize the distance traveled by film strips  718 , which may be susceptible to tearing, before being bonded with non-woven webs  713 ,  715 . Likewise, film strips  718  move in the machine direction of in-line lamination system  710  and do not experience lateral changes in direction to minimize stress on film strips  718  before lamination with non-woven webs  713 ,  715 . Laminate sheets  717 ,  719  move through in-line lamination system  710  for roll-up or further processing at the selection of an operator. In some embodiments, during later processing, such as during formation of a laminate product  90  as described above, the adhesive applied to film strips  718  allows bonding of facing film strips  718  as portions of laminate sheets  717 ,  719  are bonded together, such as by ultrasonic welding. 
     Another embodiment of an in-line lamination system  810  in accordance with the present disclosure is shown in  FIG.  17   . In-line lamination system  810  is similar to in-line lamination system  710  and includes a film slitter  812  and a laminator  814 . A film  816 , such as a breathable or elastic plastic film, passes through slitter  812  to divide film  816  into strips  818 . Strips  818  pass through laminator  814  to bond with the respective non-woven webs  813 ,  815  to form separate laminate sheets  817 ,  819  having alternating sections of exposed non-woven material and film laminated to and covering a portion of the underlying non-woven material. 
     In the illustrative embodiment, laminator  814  includes adhesive applicators  822  and lamination nip rollers  824  as shown in  FIG.  17   . A non-woven material supply  826  includes supply rolls  823 ,  825  for feeding non-woven webs  813 ,  815  into lamination nip rollers  824 . Film strips  818  pass through lamination nip rollers  824  such that non-woven web  813  extends along an upper side of film strips  818  and non-woven web  815  extends along a lower side of film strips  818 . 
     Adhesive applicators  822  are arranged to apply an adhesive material along a width of non-woven webs  813 ,  815  as suggested in  FIG.  17   . In the illustrative embodiment, zoned anti-bond print heads  852  are arranged to apply an anti-bond material, such as a deadener, along portions of film  816  such that one side of each film strip  818  is coated where film strips  818  are not to be bonded with non-woven webs  813 ,  815 . In some embodiments, print heads  852  are arranged after slitter  812  to apply the anti-bond material onto film strips  818 . In some embodiments, print heads  852  are ink jet print heads, and the anti-bond material is in the form of an ink solution capable of passing through the ink jet print heads. The anti-bond material forms a barrier between film strips  818  and non-woven webs  813 ,  815  to block bonding of film strips  818  along the coated portions. 
     Lamination nip rollers  824  apply pressure to film strips  818  and non-woven webs  813 ,  815  to bond film strips  818  with the respective non-woven webs  813 ,  815  and form laminate sheets  817 ,  819  as suggested in  FIG.  17   . Film strips  818  block bonding together of non-woven webs  813 ,  815  as film strips  818  and non-woven webs  813 ,  815  pass through lamination nip rollers  824 . In some embodiments, lamination nip rollers  824  are heated or cooled. The anti-bond coated portions of adjacent film strips  818  are offset such that film strips  818   a ,  818   c ,  818   e  are only bonded to non-woven web  813  and the remaining film strips  818   b ,  818   d  are only bonded to non-woven web  815 . The anti-bond material applied to film strips  818  blocks film strips  818  from bonding to both non-woven webs  813 ,  815  so that separate laminate sheets  817 ,  819  can be formed. 
     Divider rollers  828  separate laminate sheets  817 ,  819  as suggested in  FIG.  17   . Adjacent film strips  818   a ,  818   b ,  818   c ,  818   d ,  818   e  diverge and are carried on non-woven webs  813 ,  815  as laminate sheets  817 ,  819  separate from one another. Film strips  818   a ,  818   c ,  818   e  form part of laminate sheet  817  while film strips  818   b ,  818   d  form part of laminate sheet  819 . The distance between film slitter  812  and laminator  814  is minimized to minimize the distance traveled by film strips  818 , which may be susceptible to tearing, before being bonded with non-woven webs  813 ,  815 . Likewise, film strips  818  move in the machine direction of in-line lamination system  810  and do not experience lateral changes in direction to minimize stress on film strips  818  before lamination with non-woven webs  813 ,  815 . Laminate sheets  817 ,  819  move through in-line lamination system  810  for roll-up or further processing at the selection of an operator. In some embodiments, during later processing, such as during formation of a laminate product  90  as described above, the adhesive applied to non-woven webs  813 ,  815  allows bonding of portions of laminate sheets  817 ,  819 , such as by passing through a set of lamination nip rollers, while facing film strips  818  are left un-bonded. 
     In illustrative embodiments, an extruded film is slit prior to lamination with a non-woven web and waste is minimized by sending alternating strips of film to an upper lamination station and a lower lamination station where either full width continuous non-woven webs are fed in, or multiple webs of non-woven are fed in, to minimize trimming of the non-woven webs during processing. Sending alternating lanes to two lamination stations allows for the gaps between strips during lamination while retaining the full area of the extruded film as good product. The system produces laminate sheets in-line, simultaneously and produces them without complex handling of narrow film strips. 
     In illustrative embodiments, the laminate sheets are produced using adhesive or ultrasonic bonding where the film is extruded, quenched, oriented, optionally printed, and then laminated to a non-woven web. The laminate sheets are then wound into rolls. The laminate sheets are separated into strips of laminate material where the film strip is about 50 percent of the width of the non-woven web. A full width of the system is used to produce the laminate sheets maximizing output.