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    Patents

    Nonwoven Materials Having Discrete Three-Dimensional Deformations with Wide Base Openings and Specif

    U.S. Patent No. 10,045,889

    09.07.18
    John Brian Strube, Okeana, OH; Jill Marlene Orr, Liberty Township, OH; James Terry Knapmeyer, Cincinnati, OH; Rodrigo Rosati, Frankfurt am Main, Germany; and Adrien Grenier, Frankfurt am Main, Germany.
    Assigned to The Procter & Gamble Company, Cincinnati, OH.

    Filed: 9/3/15
    Issued: 8/14/18

    A composite nonwoven material having a first surface and a second surface, said composite nonwoven material comprising at least two layers that are joined together, said two layers comprising a first layer and a second layer, said layers each comprising a plurality of fibers, wherein said nonwoven material comprises a generally planar first region and a plurality of discrete integral second regions that comprise deformations forming protrusions extending outward from the first surface of said nonwoven material and openings in the second surface of the nonwoven material, said protrusions being formed from fibers in each of said layers, wherein the protrusions comprise a base proximate the first surface of said nonwoven material, an opposed distal end extending outward in the Z-direction from the base, side walls between said base and said distal end of said protrusion, and a cap comprising at least a portion of the side walls and the distal end of the protrusions, wherein multiple fibers extend from the base of the protrusions to the distal end of the protrusions, and contribute to form a portion of the sides and cap of a protrusion, wherein a portion of said second layer is positioned inside a portion of said first layer in said protrusions, wherein a portion of the fibers in the first layer form part of: the first region, the side walls of the protrusions, and the distal ends of the protrusions; and a portion of the fibers in the second layer form part of: the first region, the side walls of the protrusions, and the distal ends of the protrusions; wherein: a) the concentration of fibers in the first region of the first layer is greater than the concentration of fibers in the distal ends of the protrusions in said first layer; and b) the concentration of fibers in the second layer in the first region and the distal ends of the protrusions is greater than the concentration of fibers in the side walls of the protrusions in said second layer.
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