Molded substrate with highly textured surface

Abstract

The present disclosure generally relates to shaped substrates for producing highly textured nonwoven webs. The shaped substrate includes a pattern of raised elements. Each raised element is formed of a plurality of layers. In accordance with the present disclosure, each raised element includes a base layer having at least one dimension that is greater than or longer than the same or corresponding dimension on one or more height build layers deposited on top of the base layer. In this manner, the pattern of raised elements remains in registration with the base layer even if the underlying substrate experiences a dimensional change during the process of creating the raised elements.

Description

BACKGROUND OF THE INVENTION

[0001] Fiber nonwoven web materials are widely used in many applications, including but not limited to absorbent structures and wiping products, many of which are disposable. In particular, such materials are commonly used in personal care absorbent articles such as diapers, diaper pants, training pants, feminine hygiene products, adult incontinence products, bandages, and wiping products such as baby and adult wipes. They are also commonly used in cleaning products such as disposable wet and dry wipes that can be treated with a cleaning agent and other compounds designed for use by hand or in combination with a cleaning device such as a mop. Another application is beauty aids such as cleaning pads and wipes, as well as makeup removing pads and wipes.

[0002] In many of these applications, three-dimensionality and increased surface area are desirable properties and can be imparted by a variety of processes that texture or emboss the surface of the nonwoven web. Patterning forming wires can be used to effect texturing or decorative lines on nonwoven products. However, as thicker and more structured nonwoven products become increasingly popular, it has proven challenging to provide patterning forming wires that can provide sufficient surface texturing.

[0003] To form a nonwoven web with a highly textured surface, forming wires with larger pattern or element heights have been produced to improve the surface texture of the nonwoven products produced on the forming wires. In the relatively recent past, additive manufacturing or three-dimensional printing has been used to form topographical patterns on the forming wires. However, one problem encountered is being able to print topographical patterns on a forming wire that is durable and does not degrade or wear over time. Thus, in order to form raised pattern elements on the forming wire, a polymer must be deposited at a high temperature on the forming wire made of polymer filaments. In this way, the heated polymer material deposited on the forming wire not only impregnates the forming wire in the void spaces and gaps, but also forms a strong bond with the polymer filaments. However, exposing the forming wire to the high temperature polymer material can cause the forming wire to undergo a change in length. For example, the length of the forming wire may shorten.

[0004] While these changes in the length of the forming wire are relatively small on a local scale, these changes can cause the patterns printed on the forming wire to lose alignment, especially over longer lengths. Thus, there is a current need for a process and method for forming raised pattern elements on a forming wire using additive manufacturing while maintaining pattern alignment even if the forming wire undergoes dimensional changes during the process. SUMMARY OF THE INVENTION

[0005] Generally speaking, the present disclosure relates to printing or depositing multi-layer patterns on a formed substrate while subjecting the formed substrate to dimensional irregularities. By the method of the present disclosure, the length or width of the formed substrate can be changed while the multi-layer patterns remain aligned and registered. According to the present disclosure, the pattern applied to the formed substrate includes a base layer or a first layer that adheres to the formed substrate and is embedded in the woven material of the fabric forming the substrate. The base layer has a sufficient size and dimension to allow subsequent layers to be formed on top of the base layer and to maintain alignment and registration even when the formed substrate undergoes dimensional instability and / or changes in length or width.

[0006] In this regard, the present disclosure relates to a formed substrate including a fabric. The formed substrate includes a top surface, a bottom surface opposite the top surface, an x-y plane, and a thickness extending from the bottom surface to the top surface in a z-direction perpendicular to the x-y plane. The substrate is made of a plurality of filaments in a manner that forms voids between the filaments. The formed substrate further includes a pattern of raised elements positioned on the top surface of the substrate. The raised elements include at least two layers of a polymer material. More specifically, each raised element includes at least one base layer and at least one height building layer positioned on top of the at least one base layer. The base layer has at least one dimension in the x-y plane that is greater than the same or corresponding dimension of the at least one height building layer. For example, the at least one dimension can be a length, a width, or a diameter. The at least one dimension of the base layer can be greater than the corresponding dimension on the at least one height building layer by about 3%, such as greater than about 5%, such as greater than about 8%, such as greater than about 10%, such as greater than about 12%, such as greater than about 15%, such as greater than about 18%, such as greater than about 20%, such as greater than about 23%, such as greater than about 25%, such as greater than about 28%, such as greater than about 30%, and generally less than about 60% of the corresponding dimension on the at least one height building layer, such as less than about 40%, such as less than about 30%. In one aspect, each raised element can include a plurality of height building layers, which typically have the same shape or form a taper.

[0007] In one aspect, the pattern of the raised elements can include a pattern of discrete shapes. Alternatively, the pattern can include a continuous pattern. In yet another embodiment, the pattern can include a combination of a continuous pattern and discrete shapes. For example, the pattern can include circles, ellipses, triangles, crosses, squares, rectangles, diamonds, hexagons, other polygons, lines, swirls, stars, characters, badges, or combinations thereof. The raised elements can generally have a height of at least about 0.1 mm, such as at least about 0.25 mm, such as at least about 0.5 mm, such as at least about 1 mm, such as at least about 1.5 mm, such as at least about 2 mm, such as at least about 2.5 mm, such as at least about 3 mm, such as at least about 3.5 mm, such as at least about 4 mm, and generally less than about 10 mm, such as less than about 8 mm, such as less than about 7 mm.

[0008] In one aspect, the base layer can be longer than at least one height build layer in the longitudinal direction of the shaped substrate. The base layer can be longer than the height build layer in more than one dimension, such as at least in two dimensions. In one aspect, the base layer can have the same shape as the height build layer, but can have a larger surface area. In one aspect, during the method, the height build layer can be positioned offset from the center of the base layer, especially when the shaped substrate undergoes dimensional changes during three-dimensional printing.

[0009] The plurality of filaments contained within the shaped substrate can be formed of a thermoplastic resin, silicone rubber, or non-silicone vulcanized rubber. The base layer of each raised element can be positioned adjacent to the top surface of the substrate, where the base layer surrounds and / or fuses to one or more substrate filaments. In another aspect, the melting point of the polymer material of the base layer differs from the melting point of the substrate by about 20% or less.

[0010] In one aspect, the substrate is polyethylene terephthalate. Additionally or alternatively, the polymer material used to form the raised elements can be ethylene glycol-modified polyethylene terephthalate. In another aspect, the polymer material of the raised elements is disposed on the substrate by additive manufacturing, preferably where the polymer material is disposed on the substrate by a fused deposition modeling (FDM) process.

[0011] The present disclosure also generally relates to a method of manufacturing a shaped wire according to any one or more of the above aspects. The method includes: forming a continuous pattern of raised elements on the substrate by dispensing a base layer from an extrusion head that is conveyed along the x-plane and / or y-plane on the top surface of the substrate, where at least a portion of the voids are filled with a polymer material, and dispensing one or more additional height build layers of the polymer material onto the first polymer material layer until the pattern height is reached.

[0012] In addition, the present disclosure generally also relates to a method of disposing multiple fibers on a formed wire to form a web and drying the web.

[0013] Other features and aspects of the invention are set forth in more detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present disclosure is set forth more fully and made enabling in the remainder of the specification with reference to the drawings, in which:

[0015] Figure 1 is a fragmented top plan view of a substrate of the present disclosure;

[0016] Figure 2 is a cross-sectional view of a substrate of the present disclosure;

[0017] Figure 3 is a cross-sectional view of a formed substrate including raised elements manufactured in accordance with the present disclosure;

[0018] Figure 4 is a cross-sectional view of a formed substrate showing another embodiment of raised elements in accordance with the present disclosure;

[0019] Figure 5 is a perspective view of one embodiment of a formed substrate manufactured in accordance with the present disclosure including a pattern of raised elements;

[0020] Figure 6 is another perspective view of one embodiment of a formed substrate manufactured in accordance with the present disclosure including a pattern of raised elements;

[0021] Figure 7 is another perspective view of one embodiment of a formed substrate manufactured in accordance with the present disclosure including a pattern of raised elements; and

[0022] Figure 8 is Figure 7 a partial cross-sectional view of the illustrated formed substrate.

[0023] The repeated use of reference numerals in this specification and the drawings is intended to represent the same or analogous features or elements of the invention.

[0024] Definition

[0025] As used herein, the terms "about," "approximately," or "substantially" when used in reference to a value mean that the value can increase or decrease by 10% (e.g., such as 7.5%, 5%, such as 4%, such as 3%, such as 2%, such as 1%) and remain within the disclosed aspect. Additionally, the term "substantially free of" when used to describe the amount of a substance in a material is not limited to being completely or entirely free of, and can be equivalent to the absence of any perceptible or detectable amount of the listed substance in the material. Thus, for example, a material is "substantially free of" the above substance when the amount of the substance in the material is less than the precision of the industry-recognized instrument or test used to measure the amount of the substance in the material. In certain example aspects, a material can be "substantially free of" the above substance when the amount of the substance in the material is less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4%, less than 3%, less than 2%, less than 1%, less than 0.5%, or less than 0.1% by weight of the material.

[0026] As used herein, when the term "discrete" refers to an element disposed on the surface of a tissue product, such as a line element, a design element, or a pattern, it means that the element is visually unconnected to other elements, does not share at least one connection point with one or more adjacent elements, and / or does not continuously extend in any dimension of the tissue product surface.

[0027] As used herein, the term "fabric" refers to a cloth or paper product that includes multiple filaments and voids between the filaments. The fabric can be a woven material or a non-woven material, and can include a papermaking / non-woven forming fabric or a product made from a tissue web (e.g., bath towels, facial tissues, paper towels, wipes (e.g., industrial, food service, or personal care wipes), napkins, medical pads, etc.). The fabric can be made by a variety of processes, including but not limited to airlaid processes, wetlaid processes (such as using cellulose-based tissue or towels), hydroentanglement processes, short fiber carding and bonding, solution spinning, or uncreped through-air drying (UCTAD) processes. The fabric can be made from a variety of materials, including natural fibers, synthetic fibers, or combinations thereof. As discussed in more detail below, the terms "forming wire" and "forming fabric" are used interchangeably herein.

[0028] As used herein, "pattern" or "decorative pattern" refers to any non-randomly repeating design, graphic, or motif. The elements of the pattern need not form a recognizable shape, and the repeated design of the elements is considered to constitute a decorative pattern.

[0029] As used herein, the term "Solid Freeform Fabrication" (SFF) generally refers to the three-dimensional printing of materials using any of a number of well-known layer fabrication processes, such as stereolithography, selective laser sintering, inkjet printing, laminated object manufacturing, fused deposition modeling, laser-assisted welding or cladding, and shape deposition manufacturing. SFF generally involves representing a 3D object using a computer-aided design (CAD) geometry file, converting the design file into machine control commands, and using those commands to drive and control a part building tool to build the part in a point-by-point or layer-by-layer fashion.

[0030] As used herein, the term "additive manufacturing" refers to manufacturing techniques for forming three-dimensional objects or components by adding materials layer by layer. Additive manufacturing processes include solid freeform fabrication and fused deposition modeling processes.

[0031] As used herein, the term "3D printing" generally refers to the fused deposition modeling process (hereinafter simply referred to as FDM) as described in U.S. Patent 5,121,329, the content of which is hereby incorporated by reference in a manner consistent with this disclosure, and generally employs a heated nozzle to melt and extrude materials. The build material is supplied to the nozzle in rod or filament form.

[0032] The terms "print head" or "extrusion head" are used interchangeably herein to mean the entire apparatus for transporting, melting, and applying a filament during an extrusion-based 3D printing process.

[0033] As used herein, the term "fabric" generally refers to a structure formed by a plurality of interconnected filaments. Fabrics refer to structures that include a plurality of filaments that are interconnected by weaving two or more filaments together (such as by interlacing in a repeating pattern), and to structures made by connecting a plurality of helical coils or filaments, such as the wire-connected bands disclosed, for example, in U.S. Patent No. 5,334,440.

[0034] As used herein, the term "nonwoven web" generally refers to a web having a structure of fibers or threads that are interlayered but not in an identifiable manner (such as in a knitted fabric). Examples of suitable nonwoven fabrics or webs include, but are not limited to, meltblown webs, spunbond webs, bonded carded webs, airlaid webs, coform webs, hydroentangled webs, and the like. Detailed Description

[0035] Those of ordinary skill in the art will understand that this discussion is only a description of exemplary aspects and is not intended to limit the broader aspects of the disclosure.

[0036] The present disclosure generally relates to a method and process for forming a pattern of raised elements on a shaped substrate. The raised elements are formed on the surface of the substrate in a layer-by-layer manner. In one aspect, for example, three-dimensional printing can be used to form the pattern of the raised elements on the top surface of the substrate. The first or base layer applied to the top surface of the shaped substrate should form a strong bond with the filaments of the substrate. If the base layer does not form a strong bond with the underlying shaped substrate, the raised elements may have a tendency to wear over time. In one embodiment, to form a strong bond between the base layer and the shaped substrate, the shaped substrate is made of polymer filaments and the base layer is made of a polymeric material. The polymeric material is applied to the shaped substrate at a relatively high temperature, such as greater than about 200 °C, such as greater than about 250 °C, such as greater than about 270 °C, and generally less than about 300 °C, such as less than about 290 °C. Applying the base layer at a high temperature may cause the surface of the filaments to melt and form a bond with the polymeric material. Additionally, the polymeric material can impregnate the shaped substrate at a high temperature, bonding not only to the filaments in the substrate but also filling the void spaces in the substrate, thereby forming a strong and stable layer for generating the raised elements.

[0037] However, one problem encountered is that the shaped substrate or fabric may undergo dimensional changes due to exposure to high-temperature polymeric materials or other external forces. For example, applying a high-temperature polymeric material to the shaped substrate to form the base layer may cause a change in the length of the shaped substrate and, in one embodiment, may cause the shaped substrate to shorten. Although these changes in the dimensions of the shaped substrate are small on a local scale, they can have an adverse effect on the ability to form a pattern of raised elements on the shaped substrate over a longer length range. Specifically, the dimensional changes of the shaped substrate may cause the pattern of the raised elements to lose alignment. For example, if subsequent layers of the raised elements are not aligned with the base layer, the raised elements may not form a strong bond with the top surface of the shaped substrate and may wear or break.

[0038] To address the above problems, the present disclosure relates to a method for forming a pattern of raised elements on a shaped substrate that can undergo dimensional changes, such as length instability. According to the present disclosure, a base layer or first layer is applied to the shaped substrate, which has at least one dimension, such as diameter or perimeter, that is greater than other layers applied to the base layer to form the raised elements. Increasing the size of the base layer in at least one dimension relative to the top layer allows the pattern to accommodate any changes or offsets in the length of the shaped substrate. In this way, a complex pattern of raised elements can be formed on the shaped substrate while maintaining durability.

[0039] All different types of patterns can be applied to the shaped substrate according to the present disclosure. For example, the pattern of raised elements can be a pattern of discrete shapes, or can be a continuous pattern, such as a grid pattern. In yet another aspect, the pattern of raised elements can include discrete shapes combined with continuous elements.

[0040] Each of the raised elements formed on the shaping surface can have any suitable shape. Examples of possible shapes for forming the pattern include, but are not limited to, circular, oval, triangular, cross-shaped, square, rectangular, diamond-shaped, hexagonal, other polygons, lines, swirls, star-shaped, characters, badges, etc., and combinations thereof.

[0041] In one aspect, the pattern can be formed on the substrate by additive manufacturing (especially SFF, such as fused deposition modeling (FDM) process). For example, in one aspect, three-dimensional (3D) elements can be fabricated on the substrate using additive manufacturing to form the pattern.

[0042] In one aspect, using additive manufacturing (such as FDM) to produce a patterned substrate having 3D elements or decorative patterns thereon can include forming a polymer base layer on the substrate prior to forming additional layers of the pattern. In some aspects, the polymer base layer can provide a platform for adding subsequent layers without damaging or compromising the strength of the substrate, thus allowing subsequent layers to be printed more quickly. In some aspects, the polymer base layer can also improve the adhesion of the FDM 3D elements to the surface of the fabric substrate by providing an adhesion surface for the subsequent layers. According to the present disclosure, the size of the base layer is adjusted so that even if the shaped fabric undergoes dimensional changes, the top layer can still be registered with the base layer.

[0043] An initial layer of polymer material is used to form the first or base layer of the pattern, and the formation is carried out by dispensing a flowable polymer material from an extrusion head that is conveyed over the top surface of the substrate onto the surface of the substrate. The flowable polymer material has a viscosity low enough to allow the flowable polymer material to flow into the void spaces present in the substrate. More specifically, when the flowable polymer material contacts the substrate, it flows into and around the filaments forming the substrate and into the voids, where the flowable polymer material and the extrusion head partially melt and / or soften the substrate itself. Thus, as the flowable polymer material and the substrate cool, the flowable polymer material and the substrate solidify together, allowing the flowable polymer material to take the shape of the voids and surround the filaments, and in addition, fusing the first layer of the flowable polymer material and the substrate together to mechanically fix the first flowable polymer layer or base layer to the substrate. Then additional flowable polymer layers forming the pattern can be printed onto the substrate on the base layer.

[0044] Generally, any suitable polymeric material can be used to form the base layer of the raised element. In one aspect, the melting point of the polymeric material used to form the base layer can differ from the melting point of the polymeric material of the filaments used to form the shaped substrate by about 20% or less, such as about 17.5% or less, such as about 15% or less, such as about 12.5% or less, such as about 10% or less, such as about 7.5% or less, such as about 5% or less, such as about 2.5% or less, or any range or value therebetween. Additionally, in one aspect, the melting point of the flowable polymeric material, the melting point of the substrate, or both of them is about 350 °C or lower, such as about 325 °C or lower, such as about 300 °C or lower, such as about 275 °C or lower, such as about 250 °C or lower, such as about 225 °C or lower, such as about 150 °C or higher, or any range or value therebetween. That is, when selecting the melting point of the flowable polymeric material used to form the base layer, the melting point of the substrate, or both of them according to the above, the extrusion head can sufficiently soften the flowable polymeric material, the substrate, or both of them, thereby providing strong adhesion between the flowable polymeric material and the substrate.

[0045] The shaped substrate can be formed from any suitable material that includes multiple filaments and voids between the filaments. The substrate can be, for example, a woven material or a non-woven material. The substrate can be a single layer or contain multiple layers. Examples of suitable substrates are described, for example, in WO 2019 / 028052 and US 2018 / 0209096, which are incorporated herein by reference.

[0046] The filaments (also referred to herein as "fibers") forming the substrate can be made of a variety of materials. For example, the filaments can include a thermoplastic resin, silicone rubber, or a non-silicone vulcanized rubber made of at least a majority weight of a fluorine-containing elastomer having good heat resistance and chemical resistance. Suitable thermoplastic resins that can be used include, but are not limited to: polyvinyl fluoride, polyvinylidene fluoride, polyvinyl chloride, polyethylene, polypropylene, polyethers, styrene-butadiene copolymer, polybutene, polyethylene ("PE"), polypropylene ("PP"), polyphenylene sulfide ("PPS"), polyimide, polyamide, polysulfone, polysulfide, cellulose resin, polyarylate acrylate, polyarylsulfone, polyurethane, epoxy resin, poly(amide-imide), copolyester, polyethersulfone, polyetherimide, polyarylether, etc., as well as combinations and copolymers thereof. In other cases, the substrate can contain silicone rubber. In still other cases, the substrate can include a fluorine-containing elastomer layer bonded to a silicone rubber layer. In one aspect, the substrate contains polyphenylene sulfide. However, in one aspect, the substrate is formed of a polyester (such as, in one aspect, polyethylene terephthalate (PET)).

[0047] Regardless of the substrate material selected, there will be voids between the filaments of the substrate. To assist the flowable polymer material of the first layer in filling the voids, in some aspects, it is desirable for the voids in the substrate to have a diameter of at least 100 μm. In one aspect, the distance between the voids is approximately equal to the extrusion width distance, or less.

[0048] For example, refer to Figure 1 , which depicts a partial top plan view of an exemplary formed substrate 10 (also referred to herein as a formed wire or fabric substrate). The substrate 10 is in the x-y plane and includes a plurality of filaments 14 and voids 15 between the filaments. In aspects where the substrate is a formed wire, the substrate 10 can have two main dimensions - longitudinal ("MD") (which is the direction parallel to the main direction in which the fabric travels during manufacturing within the plane of the tape 10) and transverse ("CD") (which is generally orthogonal to the longitudinal direction). The substrate 10 is generally liquid and air permeable. The substrate can be any fabric material that includes void spaces within or between the filaments forming the substrate. For example, the substrate can be a woven fabric or a non-woven fabric. In a particularly preferred aspect, the substrate is a woven fabric.

[0049] Refer to Figure 2 , which depicts a cross-sectional view of another exemplary substrate 20. The substrate 20 is in the x-y plane and has a top surface 21, a bottom surface 22 opposite the top surface, and a thickness 23 extending from the bottom surface to the top surface along the z direction perpendicular to the x-y plane. The substrate 20 includes a plurality of filaments 24 and voids 25 between the filaments. In one aspect, the substrate can be substantially planar, or can have a three-dimensional surface defined by ridges. As Figure 2 shown, in one aspect, the top surface 21 of the substrate 20 has an uneven topography, where some points of the filaments are higher than other points of the filaments. In one aspect, the substrate 20 can be constructed such that the highest points of the filaments 24 are substantially coplanar and form the top 26 of the substrate.

[0050] Although the substrates of the present disclosure are generally planar, the topography of the substrate surface can vary. This is shown, for example, in Figure 2 , which shows an exemplary substrate where the height of the filaments in the substrate extending in the z direction varies. In some cases, it may be desirable to determine the highest point at which the filaments in the substrate extend in the z direction (e.g., the highest point of the top surface) to ensure that the extrusion head is set at a height sufficient to produce a polymer material that extends onto the top surface of the substrate. This point (i.e., the highest point of the top surface) is referred to herein as the "top" of the substrate.

[0051] Regardless of the substrate selected, the polymeric material (also referred to herein as "polymeric pattern material" or "polymeric material") used to form the first pattern layer or base layer, additional pattern layers, or the entire pattern can be any material that can be used in an additive manufacturing process such as FDM. Specifically, the polymeric material can be any material that can be melted into a flowable state and re-solidify in the voids in the substrate. Examples of suitable materials include thermoplastics, epoxy resins, other polymeric materials, and combinations thereof. In some aspects, the polymeric material includes thermoplastic polymers, e.g., thermoplastic polymers containing from about 0.5 wt% to 10 wt% of silicone and a base polymer such as polyethersulfone, polyetherimide, polyphenylsulfone, polyphenylene, polycarbonate, high impact polystyrene, polysulfone, polystyrene, acrylic, amorphous polyamide, polyester, nylon, PEEK, PEAK, and ABS.

[0052] Due to the microscale gaps, the polymeric material can be a thermoplastic polymer with improved rigidity compared to silicone, nylon, ABS, etc. Thus, in one aspect, the polymeric material is PET (polyester), PPS (polyphenylene sulfide), PCTA (polyethylene terephthalate cyclohexanedimethylene ester), PEN (polyethylene naphthalate), PVDF (polyvinylidene fluoride), PEEK (polyetheretherketone), their derivatives, and combinations thereof. In a particular aspect, the polymeric material is an ethylene glycol modified polyester, such as, in one aspect, polyethylene terephthalate glycol (PETG).

[0053] However, in one aspect, any polymeric material with sufficient rigidity can be used. For example, the polymeric material used herein can have a Shore A hardness of about 60 or greater, such as about 62.5 or greater, such as about 65 or greater, such as about 67.5 or greater, such as about 70 or greater, or any value or range therebetween, as measured according to ASTM D2240. Additionally or alternatively, the polymeric material can have a Shore D hardness of about 50 or greater, such as about 52.5 or greater, such as about 55 or greater, such as about 57.5 or greater, such as about 60 or greater, or any value or range therebetween, as measured according to ASTM D2240.

[0054] In one aspect, substrate materials and polymer materials having substantially similar properties in the polymer structure should be selected to provide strong bonding / adhesion between the first polymer layer or base layer and the substrate. For example, a PET substrate and a PETG first polymer layer have excellent bonding strength due to their similar hydrophobicity and melting temperatures. Thus, in one aspect, the substrate and polymer materials can be selected from any one or more of the substrates and polymer layers listed above, but polymers having similar melting temperatures as discussed above and selected from similar classes that provide excellent adhesion between the substrate and the first polymer layer can also be chosen.

[0055] In some aspects, the polymer material can also include various additives, such as carbon fibers or other additives that can improve the processability or physical characteristics of the finished product. The polymer material can also include photocurable resins and self-curing resins. Photocurable resins can include resins that can be cured by ultraviolet light, visible light, electron beam, γ-radiation, radio frequency, microwave, infrared radiation, or other known curing methods involving the application of radiation to cure the resin. Suitable resins can also include those that can be cured by chemical reactions without the addition of radiation, such as the curing of epoxy resins, the extrusion of self-curing polymers (such as polyurethane mixtures), thermal curing, the application of hot melt, or the solidification of molten thermoplastics.

[0056] As discussed herein, the polymer material is dispensed onto the substrate in a flowable state. When in a flowable state, the polymer material is also referred to herein as a "flowable material" or a "flowable polymer material". To obtain a flowable polymer material, the polymer material is heated to at least the melting point of the material prior to dispensing. The ability of the flowable polymer material to fill voids in the substrate can be affected by the diameter of the voids in the substrate and the viscosity of the flowable polymer material. Specifically, it should be understood that the lower the viscosity of the flowable polymer material, the easier it is for the flowable polymer material to flow into the voids in the substrate. Specifically, when the void diameter or void volume is small, a lower viscosity is desirable. Thus, the flowable polymer material preferably has a low enough viscosity to penetrate deep enough into the voids in the substrate to create mechanical tension upon cooling. In one particular aspect, the flowable polymer material will advantageously have a low enough viscosity to allow the flowable polymer material to penetrate into the substrate to a depth of at least 50% of the substrate thickness.

[0057] The polymeric material can be heated to any temperature at which the material is flowable, including heating to at least the melting point of the material. In some aspects, it may be desirable to heat the polymeric material to a temperature above its melting point. Specifically, dispensing the polymeric material onto the substrate at a higher temperature can keep the material in a flowable state for a long time while minimizing the viscosity, making it easier to fill voids in the substrate. As discussed above, dispensing the polymeric material onto the substrate at a high temperature can also help maximize the adhesion between the flowable polymeric material in the substrate and the filaments. Thus, in some aspects, the polymeric material can be heated to a temperature that is at least 10 °C, at least 20 °C, at least 30 °C, at least 40 °C, at least 50 °C, at least 60 °C, at least 70 °C, at least 80 °C, at least 90 °C, at least 100 °C, at least 150 °C, or at least 200 °C higher than the melting point of the material before dispensing the polymeric material as a flowable polymeric material onto the substrate.

[0058] It should be understood that it is also possible to dispense a polymeric material heated to a temperature above the melting point / ignition point of the substrate without damaging the substrate itself. Specifically, the heat capacity of the substrate can be affected by factors other than the temperature of the flowable polymeric material and the melting point / ignition point of the substrate. For example, the volume of polymeric material extruded per unit linear distance traveled by the extrusion head (the greater the extruded volume, the more heat is applied to the substrate), the filament size (the finer the filaments in the substrate, the lower the heat capacity of the substrate), and the printing speed (the slower the printing speed, the more heat is transferred by the heated extrusion head, which may melt / burn the fabric) can all affect the integrity of the substrate and the amount of heat the substrate can absorb without being damaged. Thus, in other aspects, the polymeric material can be heated to a temperature at least equal to the melting point of the polymeric material and also heated to a temperature above the melting point (or ignition point) of the substrate.

[0059] However, when the polymeric material is dispensed onto the shaped substrate at a high temperature, the shaped substrate may undergo dimensional changes, such as shortening in length. However, as described in more detail below, a raised pattern element is formed in accordance with the present disclosure, the raised pattern element including a base layer having a surface area sufficient to cause any dimensional changes that the shaped substrate may undergo.

[0060] As discussed herein, it is desirable to maximize the penetration of the flowable polymeric material into the voids of the substrate. Thus, in one aspect, the penetration of the flowable polymeric material into the voids of the substrate can be facilitated by dispensing the flowable polymeric material onto a heated substrate. By dispensing the flowable polymeric material onto a heated substrate, the flowable polymeric material does not cool rapidly, allowing the flowable polymeric material more time to penetrate and fill the voids of the substrate before solidifying.

[0061] Accordingly, in another aspect, the method of the present disclosure may further include heating a substrate before forming the polymer material layer. The substrate can be heated to any temperature at which the substrate is not damaged (e.g., melted or degraded). In one aspect, the substrate is heated to a temperature of at least 70°C, or at least 80°C, at least 90°C, at least 100°C, at least 110°C, at least 120°C, at least 130°C, at least 140°C, at least 150°C, at least 180°C, at least 200°C, at least 220°C, at least 250°C or at least 270°C. In one aspect, the substrate is heated to a temperature below the melting point of the substrate, including a temperature that is 1°C, 2°C, 5°C, 10°C, 15°C, 20°C, 30°C, 40°C, 50°C, 60°C, 70°C, 80°C, 90°C or 100°C lower than the melting point of the substrate. Any suitable means known in the art for heating a fabric substrate can be used to heat the substrate. In one aspect, during 3D element formation, the substrate is placed on a support plate or a support belt, and the substrate is heated by heating the plate or the belt to a desired temperature. In one aspect, the flowable polymer material does not undergo a cooling step after being dispensed onto the substrate, but solidifies at ambient temperature. Accordingly, in another aspect, the extrusion head does not contact the top surface of the substrate when forming the polymer layer.

[0062] See Figure 3 , which shows an embodiment of a formed substrate 30 manufactured according to the present disclosure. In this embodiment, the formed substrate 30 consists of a woven fabric made from polymer filaments 34. The fabric is woven to form voids 32 within the formed substrate 30.

[0063] According to the present disclosure, a pattern of raised elements 35 is formed on the top surface of the formed substrate 30. The raised elements 35 are formed on the substrate 30 in a layer-by-layer manner. The raised elements 35 include at least one base layer 36 adjacent to and in contact with the top surface of the substrate 30. There are a plurality of height build-up layers 38 on top of the base layer 36.

[0064] As described above, the base layer 36 is formed at a high temperature in such a way that the polymer material of the base layer 36 fills the voids 32 in the substrate 30 and surrounds the filaments 34 of the substrate. The polymer material of the base layer 36 extends in the z-direction into and above the top of the substrate 30.

[0065] Establishing a good bond between the base layer 36 and the substrate 30 allows the height build-up layers 38 to be subsequently applied to the substrate and have the required durability during use, such as during the production of a nonwoven web. However, applying the base layer 36 at a high temperature may cause dimensional changes within the substrate 30, especially in the length direction. Specifically, the length of the substrate 30 can be shortened on a local scale. Accordingly, according to the present disclosure, as Figure 3As shown, the base layer 36 has at least one dimension that is greater than the same or corresponding dimension of the height build layer 38. For example, in one aspect, the length of the base layer 36 can be greater than the length of the height build layer 38. Alternatively, the perimeter or circumference of the base layer 36 can be greater than the perimeter or circumference of the height build layer 38.

[0066] According to the present disclosure, at least one dimension of the base layer 36 is at least about 3% of the same or corresponding dimension of the height build layer 38, such as greater than about 5% of that dimension, such as greater than about 8%, such as greater than about 10%, such as greater than about 12%, such as greater than about 15%, such as greater than about 18%, such as greater than about 20%, such as greater than about 23%, such as greater than about 25%, such as greater than about 28%, such as greater than about 30%. The amount by which the at least one dimension is larger than the same or corresponding dimension of the height build layer 38 is generally less than about 60%, such as less than about 50%, such as less than about 40%, such as less than about 35%.

[0067] In Figure 3 In the illustrated embodiment, the raised element 35 includes four height build layers. However, it should be understood that the raised element 35 can include at least one and up to about 20 height build layers 38. For example, the raised element 35 can include at least two, such as at least three, such as at least four, such as at least five, such as at least six height build layers 38.

[0068] The raised element 35 is used to impart texture to the nonwoven web manufactured on the forming substrate 30. In this regard, the raised element 35 can extend from the top surface of the forming substrate 30 by an amount greater than about 0.1 mm, such as greater than about 0.25 mm, such as greater than about 0.5 mm, such as greater than about 1 mm, such as greater than about 1.5 mm, such as greater than about 2 mm, such as greater than about 2.5 mm, such as greater than about 3 mm, such as greater than about 3.5 mm, such as greater than about 4 mm, such as greater than about 4.5 mm, and generally less than about 10 mm, such as less than about 9 mm, such as less than about 8 mm, such as less than about 7 mm, such as less than about 6 mm, such as less than about 5 mm.

[0069] In Figure 3 In the illustrated embodiment, the height build layers 38 all have the same circumference or perimeter. During three-dimensional printing, registration is established after applying the base layer 36 to form the raised element 35. Due to the dimensional instability of the forming substrate 30, the height build layers 38 may deviate from the center positioning of the base layer. However, the size of the base layer 36 ensures that the entire circumference or perimeter of the height build layers 38 remains within the circumference or perimeter of the base layer 36.

[0070] See Figure 4, showing another embodiment of a formed substrate manufactured in accordance with the present disclosure that includes a pattern of raised elements 45. A formed substrate 40 is shown that is made of polymeric filaments 42 that form voids 44. A base layer 46 is applied to the top surface of the substrate 40 in accordance with the present disclosure, and the base layer fills the voids 42 and surrounds the filaments 44. After the base layer 46 is established, a plurality of height build layers 48 are subsequently applied to the top surface of the base layer 46. As shown, the base layer 46 has at least one dimension that is greater in size than the same or corresponding dimension of the height build layers 48 to ensure that the height build layers 48 remain registered with the base layer 46.

[0071] In Figure 4 the embodiment shown, at least one dimension of the height build layers 48 is smaller, and each layer creates a tapering effect. In this way, the raised elements 45 can be in the form of pins, cones, or any shape having a tapered side.

[0072] To form a pattern of raised elements on a formed substrate as Figure 3 and Figure 4 shown, additive manufacturing can be used. For example, in one aspect, a substrate formed of a plurality of filaments and voids therebetween having a top surface (i.e., the surface toward which the extrusion head is directed), a bottom surface opposite the top surface, an x-y plane, and a thickness extending from the bottom surface to the top surface along a z direction perpendicular to the x-y plane can be contacted with a first polymeric material, the contacting being performed by dispensing a flowable polymeric material from an extrusion head that is transported along the x direction and / or the y direction on the top surface of the substrate onto the top surface of the substrate. Additionally, as discussed above, at least a portion of the voids are filled with the flowable polymeric material. Additionally, after forming the first polymeric material or base layer, at least one additional polymeric material layer is formed on the substrate by transporting the extrusion head stepwise away from the top surface of the substrate along the z direction, wherein at least a portion of the at least one additional layer contacts the first polymeric layer or base layer. Additionally, the process is repeated until the pattern height discussed above is reached.

[0073] In one aspect, it can be advantageous to determine the spatial relationship between the substrate (fabric) and the extrusion head. More specifically, identify the top of the substrate (i.e., the highest point to which the filaments in the substrate extend in the z - direction). The top of the substrate can be identified by: i) moving the extrusion head onto the top surface of the substrate in the x - y plane without contacting the substrate; and ii) while moving the extrusion head onto the top surface of the substrate, gradually lowering the extrusion head in the z - direction towards the top surface of the substrate until the filaments of the substrate begin to degrade (e.g., melt or show damage or degradation). In one aspect, the extrusion head is moved on the top surface of the substrate without dispensing polymer material. The extrusion head can be lowered towards the top surface of the substrate in any suitable increment. In one aspect, the extrusion head can be lowered towards the top surface of the substrate in increments of 60μm, 50μm, 40μm, 30μm, 20μm, 10μm, 5μm, 3μm, 2μm or 1μm until contact with the filaments is observed.

[0074] Once the top of the substrate is determined, the extrusion head can be set at a height above the top of the substrate before forming the first polymer material layer. As discussed herein, this ensures that the polymer material extends onto the top surface of the substrate. The height of the extrusion head above the top of the substrate can vary. In some aspects, the height of the extrusion head above the top of the substrate is at least 0.01mm, at least 0.05mm, at least 0.07mm, at least 0.1mm, at least 0.15mm, at least 0.17mm, at least 0.2mm, at least 0.25mm, at least 0.27mm or at least 0.3mm. In a particular aspect, the height of the extrusion head above the top of the substrate is set to 0.2mm.

[0075] Once the extrusion head height is selected, the maximum volumetric flow rate of the extruder at the selected height can be calculated. The maximum volumetric flow rate can be determined by the following process:

[0076] 1) Set up the printing press / extruder and set the desired substrate and extrusion head to the desired height.

[0077] 2) Print a series of lines approximately 50mm long while keeping the volume of material extruded per unit linear distance traveled (cm 3 / cm) constant, starting from a low speed and gradually increasing the travel speed (e.g., 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, up to 1500mm / min or higher).

[0078] 3) Visually determine the highest speed at which a constant extrusion is produced.

[0079] 4) Calculate the maximum volumetric flow rate by multiplying the travel speed of the extrusion head by the volume of material extruded per unit linear distance traveled.

[0080] In one aspect, the maximum volumetric flow rate of the extruder can be from about 0.01 to about 0.02 cm 3 / s.

[0081] Once the maximum volumetric flow rate is determined, the extrusion volume (e.g., the volume of the polymeric material) dispensed onto the substrate per a given distance traveled by the extrusion head ("volume per linear distance") can be determined. The following procedure can be used to determine the extrusion volume per a given linear distance of the extrusion head to achieve sufficient adhesion of the polymeric material:

[0082] 1) Print a series of patterns having 2D features (e.g., circles, squares, or some other non-linear shapes) on the substrate. This allows testing the adhesion of the polymeric material in different printing directions. Print each set of patterns at different cm 3 / cm values at a suitable speed to maintain the calculated maximum volumetric flow rate at the selected extrusion head height.

[0083] 2) Conduct a peel adhesion test on the patterns. The test can include, for example, bending the fabric at a very large radius and attempting to mechanically pry the polymeric material off the substrate.

[0084] Then, the extrusion volume (e.g., the volume of the polymeric material) per a given distance traveled by the extrusion head (cm 3 / cm) that balances the desired printing speed and quality can be selected. The appropriate extrusion volume per a given distance traveled by the extrusion head can vary widely depending on the extruder used and the final design of the 3D element to be printed. In one aspect, the volume per distance can be from about 0.02 to about 0.2 cm 3 / cm.

[0085] The maximum linear speed at which the printing press / extruder operates can be determined based on the maximum volumetric flow rate at the selected height and the volume per linear distance. In some aspects, a layer of polymeric material is formed by conveying the extrusion head at a linear speed of about 4 to about 40 mm / s.

[0086] As discussed above, the polymeric material forms a pattern on the surface area of the substrate. For example, the polymeric material is applied to discrete locations according to the selected pattern. In these aspects, since the polymeric material is only present at certain locations on the substrate, some voids in the substrate remain open (i.e., at locations where the polymeric material is absent), which allows for increased air permeability through the finished formed wire. In these aspects, the polymeric material forming the pattern (containing the 3D element) adheres to the substrate at discrete locations while still allowing gas to pass through the fabric.

[0087] Depending on the desired pattern height, additional layers as described herein may be used, and the additional layer may be a single layer or, more typically, a multi-layer FDM printed layer that forms a pattern on the fabric. The additional layer is formed on the substrate by moving the extrusion head along the x and / or y directions onto the top surface of the substrate to form the desired pattern while dispensing the additional flowable material. The height of the 3D element can be provided by gradually moving the extrusion head away from the top surface of the substrate along the z direction. The material used to form the additional layer may be the same as or different from the polymeric material used to form the base layer. In one aspect, the additional layer and the polymeric material are formed of the same material. In one aspect, the additional layer and the polymeric material are formed of the same material, and the extrusion head used to form the base layer is also used to form the additional layer. In some aspects, the pattern is formed by extruding a polymeric material onto the substrate, as disclosed in U.S. Patent No. 5,939,008, the content of which is incorporated herein by reference, or by printing a polymeric material onto the substrate, as disclosed in U.S. Patent No. 5,204,055, the content of which is incorporated herein by reference. In other aspects, at least in some regions, the 3D element can be produced by extruding or printing two or more polymeric materials.

[0088] In one aspect, the pattern or pattern element is formed using SFF or layer manufacturing (LM) techniques (such as the 3D printing technique described in U.S. Patent No. 5,204,055). Generally, 3D printing techniques can be employed to form an element from a series of material layers, where each layer is printed and formed on top of the previous layer.

[0089] The three-dimensional printing of the element typically begins with creating a three-dimensional computer model of the element using a suitable computer modeling program known in the art. The computer model of the element is fully segmented into a series of horizontal digital slices that define a set of slice patterns for each layer.

[0090] In one aspect, the pattern is formed using one or more print heads that span at least a portion of the width of the substrate. The print head (also referred to herein as the extrusion head) can be movable to print the material onto a static substrate, or the substrate can be movable while the print head is fixed. In any case, it is generally preferred to move the moving object at a substantially constant speed on a flat plane. In a particularly preferred aspect, a plurality of print heads extend across the width of a belt that moves on a flat plane perpendicular to the direction of travel of the substrate during printing and is preferably spaced apart at a substantially constant pitch along the substrate. However, a constant pitch of the print heads is not critical.

[0091] The printing head prints a layer of components onto the previously printed layer. Thus, the first printing head prints the first layer, the second printing head prints the second layer on the first layer, and the Nth printing head prints the Nth layer on the (n - 1)th layer. The printing head for printing additional layers can be the same as or different from the printing head for dispensing the polymer material. In one aspect, the printing head for printing additional layers is the same as the printing head for dispensing the polymer material.

[0092] The thickness of the layers is constant, and the printing heads are controlled so that in a plan view, the layers are printed on top of each other. For all printing heads, the distance from each of the printing heads to the surface it prints on is preferably also the same. Thus, the distance from the first printing head to the substrate is preferably the same as the distance from the seventh printing head to the sixth layer. This can be achieved by raising the printing heads of each layer in the order of voxel height. In this case, the droplets ejected simultaneously by the printing heads of different layers will reach the destination simultaneously.

[0093] The material printed by the printing head (for forming additional layers) can include photocurable resins and self-curing resins. Photocurable resins can include resins that can be cured by ultraviolet light, visible light, electron beam, γ-radiation, radio frequency, microwave, infrared radiation, or other known curing methods involving the application of radiation to cure the resin. Suitable resins can also include those that can be cured by chemical reactions without the addition of radiation, such as the curing of epoxy resins, the extrusion of self-curing polymers (such as polyurethane mixtures), heat curing, the application of hot melt, or the solidification of molten thermoplastics.

[0094] In one aspect, the polymer material layer is formed by an LM method including an extrusion head that extrudes heated, flowable build material from a nozzle onto a substrate. When the extrusion head and the substrate are moved relative to each other in three-dimensional space by an x - y - z gantry system, the extruded material is deposited layer by layer in the area defined by the CAD model. The material solidifies after deposition to form a three-dimensional component. The material can be a thermoplastic material that solidifies by cooling after deposition. The polymer material is deposited in the area defined by the CAD model along the lines discussed herein. That is, the CAD model or Solidworks model contains the above-discussed pattern in which the base layer is larger than the top layer.

[0095] The extrusion heads and systems suitable for preparing three-dimensional components as described above are commercially available from build machine suppliers. The extrusion head includes a liquefier and a dispensing nozzle for receiving the build material in solid form. The filament is heated to a flowable temperature inside the liquefier and then dispensed through the nozzle. Studies have shown that thermoplastic materials are particularly suitable for Deposition modeling performed in a modeling machine. A controller controls the movement of an extrusion head in a horizontal x, y plane, controls the movement of a build platform in a vertical z direction, and controls the feeding of modeling material into the head. By controlling these process variables, the modeling material is deposited layer by layer in the form of "beads" or "paths" at a desired flow rate in an area defined by a CAD model to create a three-dimensional object similar to the CAD model. The modeling material undergoes thermal solidification, and the finished model is removed from the substrate.

[0096] Now referring to Figures 5 to 8 , various embodiments of a formed substrate manufactured in accordance with the present disclosure are shown. For example, Figure 5 shows a formed substrate 50 including a pattern of raised elements 55 manufactured in accordance with the present disclosure. In this embodiment, the pattern of raised elements includes a pattern of discrete shapes or cylinders extending from the top surface of the substrate 50. As shown, each raised element 55 includes a base layer 56 having a perimeter greater than the height build layer 58 that forms a cylindrical shape. As shown, the height build layer 58 is generally offset from the center of the base layer 56.

[0097] Referring to Figure 6 , another embodiment of a formed substrate 60 manufactured in accordance with the present disclosure is shown. In this embodiment, the formed substrate 60 includes a pattern of polygonal shapes or raised elements 65. Each raised element 65 includes a base layer 66 and a plurality of height build layers 68. The base layer 66 has a perimeter greater than the height build layer 68.

[0098] Figure 7 and Figure 8 show yet another embodiment of a formed substrate 70 manufactured in accordance with the present disclosure. In this embodiment, the raised element 75 has a circular or swirling design. As Figure 8 shown, each raised element 75 includes a base layer 76 and one or more height build layers 78. As shown, the base layer 76 has a perimeter greater than the height build layer 78.

[0099] The formed substrates of the present disclosure are well suited for forming nonwoven webs and their products. Products such as wipes, absorbent articles, personal care products, and the like can benefit from the formed filaments having an increased pattern height discussed herein.

[0100] These and other modifications and variations of the present invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention more particularly described in the appended claims. Additionally, it should be understood that aspects of various embodiments may be interchanged, in whole or in part. Further, those of ordinary skill in the art will appreciate that the above description is merely exemplary and is not intended to limit the invention further described in such appended claims.

Claims

1. A forming substrate for nonwoven materials, the forming substrate comprising: A substrate having a top surface, a bottom surface opposite the top surface, an x-y plane, and a thickness extending from the bottom surface to the top surface along a z-direction perpendicular to the x-y plane, the substrate comprising a plurality of filaments and voids between the filaments; A pattern comprising at least one raised element on the top surface of the substrate, the raised element comprising at least two layers of polymer material, the at least two layers comprising at least one base layer and at least one height building layer, and wherein the base layer has at least one dimension in the x-y plane that is greater than the same dimension of the height building layer.

2. The forming substrate according to claim 1, wherein the at least one dimension is a length, a width, or a diameter.

3. The forming substrate according to any one of the preceding claims, wherein the at least one dimension of the base layer is about 5% greater, such as about 10%, such as about 15%, such as about 20%, such as about 25% greater than the same dimension of the height building layer and is about 50% smaller, such as about 30% smaller than the same dimension of the height building layer.

4. The forming substrate according to any one of the preceding claims, wherein the raised element has a height of at least about 0.1 mm, such as at least about 0.25 mm, such as at least about 0.5 mm, such as at least about 1 mm, such as at least about 1.5 mm, such as at least about 2 mm, such as at least about 2.5 mm, such as at least about 3 mm and less than about 10 mm, such as less than about 5 mm.

5. The forming substrate according to any one of the preceding claims, wherein the pattern of at least one raised element comprises a pattern of discrete shapes.

6. The forming substrate according to claim 1, wherein the pattern of at least one raised element comprises a continuous pattern.

7. The forming substrate according to claim 1, wherein the at least one dimension of the base layer is in the longitudinal direction of the substrate.

8. The forming substrate according to any one of the preceding claims, wherein the base layer has at least two dimensions in the x-y plane that are greater than the same dimensions of the height building layer.

9. The forming substrate according to any one of the preceding claims, wherein the base layer has the same shape as the height building layer but is larger in the x-y plane.

10. The forming substrate according to any one of the preceding claims, wherein the length of the substrate has changed after applying the pattern of at least one raised element to the top surface of the substrate.

11. The forming substrate according to claim 10, wherein the length of the substrate has been shortened after applying the pattern of at least one raised element to the top surface of the substrate.

12. The forming substrate according to any one of the preceding claims, wherein the height building layer is positioned eccentrically with respect to the base layer on the raised element.

13. The shaped substrate according to any one of the preceding claims, wherein the top surface of the substrate has a surface area, and wherein the pattern of at least one raised element occupies from about 10% to about 60% of the surface area of the top surface.

14. The shaped substrate according to any one of the preceding claims, wherein the pattern of at least one raised element comprises circles, ellipses, triangles, crosses, squares, rectangles, rhombuses, hexagons, other polygons, lines, spirals, stars, characters, emblems, or combinations thereof.

15. The shaped substrate according to any one of the preceding claims, wherein the plurality of filaments of the substrate are formed of a thermoplastic resin, silicone rubber, or non-silicone vulcanized rubber.

16. The shaped substrate according to any one of the preceding claims, wherein the base layer of each raised element is positioned adjacent to the top surface of the substrate, and wherein the polymeric material of the base layer surrounds and / or fuses to one or more substrate filaments.

17. The shaped substrate according to any one of the preceding claims, wherein the polymeric material of the base layer has a melting point that differs from the melting point of the substrate by about 20% or less.

18. The shaped substrate according to any one of the preceding claims, wherein the filaments of the substrate comprise polyethylene terephthalate.

19. The shaped substrate according to any one of the preceding claims, wherein the polymeric material of the at least one raised element comprises ethylene glycol-modified polyethylene terephthalate.

20. The shaped substrate according to any one of the preceding claims, wherein the polymeric material of the at least one raised element has been provided on the substrate by additive manufacturing, and wherein the polymeric material is provided on the substrate by a fused deposition modeling process.

21. A method of manufacturing a shaped wire according to any one of the preceding claims, the method comprising: forming the pattern of the at least one raised element on the substrate by dispensing from an extrusion head onto the top surface of the base layer of the substrate, the extrusion head being transported along the x-plane and / or the y-plane on the top surface of the substrate, and wherein at least a portion of the void is filled with the polymeric material, and dispensing one or more additional layers of the polymeric material onto the base layer to form one or more height build layers until a pattern height is reached.

22. A method of forming a nonwoven web, the method comprising: placing a fibrous material on a shaped substrate according to any one of the preceding claims, and forming a web from the fibrous material.

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