Kimberly-clark Corporation

Kenneth J Mitchell

Kurt W Ostermeier

John Joseph Sayovitz

Michael P Mathis

Improved method of forming bonded web laminates by application of a liquid spray between the component layers prior to application of high frequency vibrational energy commonly referred to as 'ultrasonic energy'. The liquid is preferably water and added in a minor amount, preferably less than about 25% by weight of the combined webs. The water may be added by spraying or misting and, after bonding and drying, provides improved uniformity and web bonding while allowing increased bonding rates. The method of the invention is particularly useful with heavier basis weight thermoplastic polymeric nonwoven fiber webs to be combined for durable applications such as recreational fabrics for tents and the like.

Method of ultrasonically bonding nonwoven webs

Fibrous webs are bonded by passing through a nip comprising an anvil and a hammer vibrating at high frequencies in the presence of uncombined liquid. The liquid is moved within the web causing rearrangement and entanglement of the fibers resulting in improved web properties such as strength, drape, and softness. The nature of the rearrangement and entanglement may be varied to produce random or highly entangled webs having correspondingly varying properties. Other embodiments include the use of additional fibers or other materials in the liquid or in the web and the bonding of multiple layers.

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Neenah, WI, United States of America

Kenneth J Mitchell