Method of making three-dimensional mesh

Abstract

A method of making a three-dimensional web is provided. The method includes spinning a continuous filament from a spinneret, guiding the spun continuous filament to move along a travel path having an end-guided section, and rotating a collection surface at or near the end-guided section of the travel path. The collection surface includes a recess and a platform region. The platform region is tangentially coplanar with an outer surface of the collection surface. The recess is recessed relative to an outer surface of the collecting surface. The method includes applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web having a first zone formed in the recess and a second zone formed on the plateau region. The first region and the second region differ in at least one strength characteristic. The method includes bonding the intermediate web using a bonding process to form a final three-dimensional web.

Description

Technical Field

[0001] The present disclosure relates to methods of making three-dimensional meshes, and more particularly, to methods of making three-dimensional meshes using a rotating collection surface. Background Art

[0002] Webs, such as nonwovens, are used in a variety of industries, including hygiene and medical. Within the hygiene industry, one application area for nonwovens is absorbent products, such as taped diapers, pant diapers, sanitary napkins, and adult incontinence products. These nonwovens can be used in absorbent products as topsheets, outer nonwoven covers, waistbands, front / rear ear protection (tape-type) or flaps (pant-type), flow-distribution materials, barrier materials, overlaps, and core wraps. Conventional nonwovens are typically flat and have a uniform basis weight, thickness, bulk density, opacity, and air permeability. Some consumers, particularly those in the high-end consumer segment, desire nonwovens with three-dimensional features and more intricate structures. Current technologies for producing these intricate nonwovens are costly and complex. Consequently, there is an urgent need for more cost-effective and streamlined technologies to produce these intricate nonwovens. Summary of the Invention

[0003] The present disclosure provides a manufacturing method that produces intricate three-dimensional webs in a more cost-effective and process-simplified manner than the prior art. The inventors have found an alternative to using conventional three-dimensional nonwovens to manufacture conveyor belts while achieving the same or similar benefits as such conveyor belts. The inventors have discovered that using a rotating collection surface with various surface features can produce intricate three-dimensional nonwovens. The rotating collection surface achieves a much smaller footprint than conventional nonwovens for manufacturing conveyor belts. In some cases, the rotating collection surface can be a drum, or a drum with a three-dimensional textured sleeve on top. The rotating collection surface produces high-quality three-dimensional nonwovens that are highly favored by consumers.

[0004] The present disclosure relates, in part, to a method for making a three-dimensional web. The method may include spinning continuous filaments from a spinneret, directing the spun continuous filaments along a travel path having a terminal guide section, and rotating a collection surface at the terminal guide section of the travel path. The collection surface may include a depression and a plateau region. The plateau region may be tangentially coplanar with an outer surface of the collection surface. The depression may be concave relative to the outer surface of the collection surface. The depression may have a higher fluid permeability than the raised plateau region. The method may include applying fluid pressure to the collection surface and collecting the filaments on the collection surface to produce an intermediate three-dimensional web having a first region formed in the depression and a second region formed on the plateau region. The first and second regions may differ in at least one strength characteristic, such as basis weight, bulk density, thickness, air permeability, and / or opacity. In some cases, the strength characteristic is basis weight. The strength characteristic of the first and second regions may have a value greater than zero. The method may include bonding the intermediate three-dimensional web using a bonding process (such as through-air bonding), for example, to form the final three-dimensional web.

[0005] The present disclosure also relates, in part, to a method for making a three-dimensional web. The method may include spinning continuous filaments from a spinneret, guiding the spun continuous filaments along a travel path having a terminal guide section, and rotating a collection surface at or near the terminal guide section of the travel path. The collection surface may include a platform region and a raised region. The platform region may be tangentially coplanar with an outer surface of the collection surface. The raised region may extend outward from the outer surface of the collection surface. The platform region may have a higher fluid permeability than the raised region. The method may include applying fluid pressure to the collection surface and collecting the filaments on the collection surface to produce an intermediate three-dimensional web having a first region formed on the platform region and a second region formed on the raised region. The first region and the second region may differ in at least one strength characteristic, such as basis weight, bulk density, thickness, air permeability, and / or opacity. In some cases, the strength characteristic is basis weight. The method may include bonding the intermediate three-dimensional web using a bonding process to form the final three-dimensional web. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter forming the invention, it is believed the disclosure will be better understood from the following description taken in conjunction with the accompanying drawings in which reference numerals are used to indicate substantially identical elements, and in which:

[0007] Figure 1 is a perspective view of a three-dimensional sleeve forming part of a rotating collection surface of the present disclosure;

[0008] Figure 2is a perspective view of a three-dimensional sleeve disposed above a rotating member, the three-dimensional sleeve and the rotating member together forming a rotating collection surface of the present disclosure;

[0009] Figure 3 yes Figure 2 A side view of a rotating collection surface;

[0010] Figure 4 is a perspective view of a rotating collection surface without the three-dimensional sleeve of the present disclosure;

[0011] Figure 5 is an exploded view of a portion of a first example three-dimensional sleeve or outer surface of a rotating collection surface of the present disclosure;

[0012] Figure 6 is an exploded view of a portion of a second example three-dimensional sleeve or outer surface of a rotating collection surface of the present disclosure;

[0013] Figures 7 to 12 is a schematic cross-sectional illustration of a texture in a rotating collection surface of the present disclosure as a rotating member or drum or comprising a three-dimensional sleeve disposed on a rotating member or drum;

[0014] Figure 13 is a schematic diagram of a method for making a three-dimensional mesh using the rotating collection surface of the present disclosure;

[0015] Figure 14 is a schematic diagram of a method for making a three-dimensional mesh using more than one rotating collection surface of the present disclosure;

[0016] Figure 15 is an example of an auxiliary roller engaging a portion of the rotating collection surface of the present disclosure;

[0017] Figure 16 is an example of an auxiliary roller engaging a portion of the rotating collection surface of the present disclosure;

[0018] Figure 17 is a schematic diagram of two spinnerets depositing filaments onto a single rotating collecting surface;

[0019] Figure 18 is a schematic illustration of a rotating collection surface having a support screen and a porous member; and

[0020] Figure 19 is another schematic example of a rotating collection surface with a supported screen. DETAILED DESCRIPTION

[0021] Various non-limiting forms of the present disclosure will now be described in order to fully understand the principles of the method for making a three-dimensional mesh disclosed herein in terms of structure, function, manufacture and use. One or more examples of these non-limiting forms are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the method for making a three-dimensional mesh specifically described herein and shown in the accompanying drawings are non-limiting example forms, and the scope of the various non-limiting forms of the present disclosure is limited only by the claims. The feature structures shown or described in conjunction with one non-limiting form may be combined with the feature structures of other non-limiting forms. Such modifications and variations are intended to be included within the scope of the present disclosure.

[0022] The term "absorbent article" is used herein to refer to consumer products whose primary function is to absorb and retain body exudates and waste. As used herein, absorbent articles may refer to, for example, tape-type diapers, pant diapers and / or adult incontinence diapers, or other suitable absorbent articles.

[0023] The term "machine direction" (MD) is used herein to refer to the primary direction in which a material, web, or article flows during processing. In various manufacturing and converting processes, such as bifolding, it is possible for an article to have more than one machine direction as it undergoes simultaneous processes. In other words, a production line may have an overall machine direction, but the material or article may travel in directions other than the overall machine direction as it passes through the various processes along the production line. For example, a discrete article having a rear end portion and a front end portion, each attached to a different roller and / or conveyor surface, may travel in two different directions simultaneously. In this example, both directions of travel may be considered machine directions.

[0024] The term "cross direction" (CD) is used herein to refer to a direction generally perpendicular to the machine direction.

[0025] The term "rotating collection surface" is used herein to refer to one of the following: 1) a rotating member or drum having an outer surface with a three-dimensional texture; 2) a rotating member or drum having an outer surface without a three-dimensional texture but with variable vacuum capability over at least portions of the outer surface; and 3) a three-dimensional sleeve positioned over the rotating member or drum. In all cases, both the outer surface of the rotating member or drum and the textured sleeve have areas that are permeable to fluids (e.g., air) but impermeable to the filaments. This allows for adjustment of the basis weight as the filaments accumulate on the collection surface. The rotating collection surface is not a conveyor belt and does not contain resin or light-curable resin. Due to the curved or arcuate nature of the rotating collection surface, at least portions of the rotating collection surface may not be, or do not actually be, perpendicular to at least some of the filaments being laid onto it during the filament laydown area. In other words, the rotating collection surface may not have a flat, planar portion but may instead have a curved outer circumference.

[0026] Figure 1 is a perspective view of a three-dimensional sleeve 10 that forms part of a rotating collection surface of the present disclosure. The three-dimensional sleeve 10 can have portions that are fluid-permeable and portions that impart texture to a web, such as a nonwoven fabric. The three-dimensional sleeve 10 can be configured to be placed over a rotating member or drum to form a rotating collection surface. Figure 2 1 is a perspective view of a three-dimensional sleeve 10 mounted over a rotating member or drum 12, which together with the rotating member or drum constitutes the rotating collection surface 14 of the present disclosure. The rotating collection surface, three-dimensional sleeve and rotating member or drum of the present disclosure are not conveyor belts typically used to produce nonwoven fabrics. Although Figure 2 It is not shown, but it should be understood, that the three-dimensional sleeve 10 can be textured and can have fluid-permeable portions. The rotating member or drum 12 can also have fluid-permeable portions. Thus, a vacuum can be provided by the rotating member or drum 12 and the three-dimensional sleeve 10, causing the filaments to accumulate on the rotating collection surface 14. The fluid permeability of the rotating member or drum 10 can be higher or lower than that of the three-dimensional sleeve 10. In some cases, the fluid permeability of the rotating member or drum 10 can be the same as the fluid permeability of the three-dimensional sleeve 10. Figure 3 yes Figure 2 A side view of the rotating collection surface 14 showing both the three-dimensional sleeve 10 and the rotating member or drum 12. The rotating member or drum 12 and the three-dimensional sleeve 10 may be free of resin or light-curable resin.

[0027] Figure 4 is a perspective view of the rotating collection surface 14 without the three-dimensional sleeve of the present disclosure. It should be understood that the outer surface of the rotating collection surface 14 can have textured portions and can have fluid-permeable portions so that the filaments gather on the rotating collection surface 14. In some cases, the rotating collection surface may not be textured, but rather only have fluid-permeable portions on the outer surface. In this case, a vacuum can be preferentially applied to portions of the outer surface so that the filaments are more easily adsorbed to these vacuum areas relative to areas where a vacuum may not exist. Since the filaments move into specific vacuum areas during filament laying, this may result in the formation of a web with an uneven basis weight.

[0028] Regardless of the form of the rotating collection surface (including the three forms described herein), the rotating member or roller or three-dimensional sleeve may be circular or non-circular. For example, the rotating member or roller and / or three-dimensional sleeve may be oval or other non-circular shapes.

[0029] Figure 51 is an exploded view of a portion of a first example three-dimensional sleeve or outer surface of a rotating collection surface of the present disclosure. It should be understood that texture can be imparted to a three-dimensional sleeve, or the outer surface of a rotating member or drum. The texture can include land areas 18, recesses 20, and raised areas 22. The land areas 18, recesses 20, and / or raised areas 22 can be free of resin or light-cured resin. The land areas 18 can be tangentially coplanar with the outer surface 24 of the collection surface. The rotating collection surface disclosed herein can have land areas of different sizes and / or shapes, or can have land areas that are all identical in size and / or shape. The recesses 20 can be recessed relative to the outer surface 24 of the collection surface. The recesses 20 can be recessed relative to the outer surface 24 by about 0.4 mm to about 20 mm, about 0.4 mm to about 15 mm, about 0.5 mm to about 10 mm, about 0.5 mm to about 5 mm, or about 0.8 mm to about 2.5 mm. The diameter or major dimension of the depression 20 in the XY plane (if non-circular) can be from about 0.4 mm to about 15 mm, from about 0.4 mm to about 10 mm, from about 0.4 mm to about 8 mm, from about 0.5 mm to about 6 mm, or from about 0.5 mm to about 4 mm. The depression 20 can have any suitable shape, such as circular, oval, diamond-shaped, triangular, and / or rectangular. The rotating collection surface disclosed herein can have depressions of varying sizes and / or shapes, or can have depressions that are all identical in size and / or shape. The depression 20 can have a permeable bottom surface, allowing fluid pressure (such as a vacuum) to be applied to the three-dimensional sleeve or outer surface of the rotating collection surface. The raised area 22 can extend outward from the outer surface 24 of the collection surface. The raised area 22 can extend outward from the outer surface 24 by about 0.5 mm to about 20 mm, about 0.5 mm to about 15 mm, about 0.5 mm to about 10 mm, about 1 mm to about 8 mm, about 1 mm to about 6 mm, or about 2 mm to about 5 mm. The diameter or major dimension of the raised area 22 closest to the outer surface 24 (if not circular) can be in the range of about 0.4 mm to about 15 mm, about 0.5 mm to about 10 mm, about 1 mm to about 8 mm, or about 1 mm to about 6 mm. The rotating collection surfaces disclosed herein can have raised areas of different sizes and / or shapes, or can have raised areas of all identical sizes and / or shapes. Figure 5 The textured collection surface shown can be formed into a web, such as a nonwoven, having protrusions formed in depressions 20, protrusions or openings formed by raised areas 22, and flat areas formed by land areas 18. In essence, the rotating collection surface is used to form a three-dimensional web with an intricate structure that is highly sought after by consumers.

[0030] The depression 20 may include a plurality of openings 21 so that it can have a permeable bottom surface. The opening 21 may be circular or non-circular, such as elongated or oval. For example, the diameter or major axis of the opening 21 may be in the range of about 150 microns to about 2,000 microns or about 250 microns to about 600 microns. According to known and reasonable belief, the size of the opening 21 should not be too small or too large. If the opening 21 is too small, enough vacuum may not be formed in the depression 20, thereby the filament cannot be sucked into the depression 20 and / or the depression 20 is filled with filaments. If the opening 21 is too large, the filament may overextend and partially or completely pass through the opening 21, which may cause problems when the web is released from the depression 20. In normal operation, it is expected that some filaments may partially extend through the opening 21 while still achieving an acceptable web release effect. Similar openings in the depression may have characteristics similar to those described herein.

[0031] The opening ratio of the various rotating collection surfaces discussed herein can be, for example, in the range of about 5% to about 55% or about 8% to about 40%. The opening ratio of the various rotating collection surfaces should be carefully considered to achieve a suitable three-dimensional forming effect while avoiding the following problems caused by excessively high opening ratios: insufficient mechanical strength of the rotating collection surface and / or excessive penetration of the filaments (entering the openings).

[0032] The various rotating collection surfaces discussed herein may have air permeabilities of approximately 45 m³ / s without filaments laid thereon. 3 / m 2 / min to about 300m 3 / m 2 / min, about 60m 3 / m 2 / min to about 250m 3 / m 2 / min or about 75m 3 / m 2 / min to about 200m 3 / m 2 / min range.

[0033] Figure 6 is an exploded view of a portion of a second example three-dimensional sleeve or outer surface of a rotating collection surface of the present disclosure. It will be understood that the texture can be imparted to the three-dimensional sleeve, or outer surface of a rotating member or drum. The texture can include platform areas 18 and recesses 20. The platform areas 18 can be tangentially coplanar with the outer surface 24 of the collection surface. The recesses 20 can be recessed relative to the outer surface 24 of the collection surface. The platform areas 18 and recesses 20 can be free of resin or light-curable resin. The recesses 20 can have a permeable bottom surface so that fluid pressure (such as a vacuum) can be provided to the three-dimensional sleeve or outer surface of the rotating collection surface. As Figure 6 The textured collection surface shown can be formed into a web, such as a nonwoven, having protrusions formed in depressions 20 and planar areas formed by land areas 18. In essence, the use of the rotating collection surface creates a three-dimensional web with an intricate structure that is highly sought after by consumers.

[0034] Figures 7 to 12 1 is an illustrative example of a three-dimensional texture of the following rotating collection surface contemplated for use in the present disclosure: a rotating collection surface 14 that is a rotating member or drum, or a rotating collection surface 14 that includes a three-dimensional sleeve 10 sleeved on a rotating member or drum. The rotating collection surface 14 that is a rotating member or drum, or the rotating collection surface 14 that includes the three-dimensional sleeve 10, may not contain resin or photocurable resin. Figures 7 to 12 Not drawn to scale, used only to give some idea of ​​3D textures. Figure 7 The rotating collection surface 14 is shown to include a plateau region 18 and depressions 20. The bottom portion 26 of the depressions 20 is indicated by a dashed line to indicate that it is fluid permeable. When a vacuum is applied to the bottom portion 26, the filaments 28 will accumulate in greater quantities in the depressions 20 than in the plateau region 18, as shown in FIG. Figure 7 The portion of the filaments within the depressions 20 may have different strength properties in the web than the filaments on the platform areas 18. The strength properties may be one or more of basis weight, bulk density, thickness, air permeability, and / or opacity. In some cases, the strength properties may be basis weight. Figure 7 In this example, the portion of the web within the depressions 20 will have a higher basis weight, bulk density, thickness, air permeability, and / or opacity than the portion of the web on the platform area 18. The higher concentration of filaments 28 in the depressions 20 is due to the fact that the vacuum is primarily supplied to the depressions 20. The present disclosure also encompasses providing vacuum or fluid pressure to the platform area 18, but the vacuum or fluid pressure may generally be lower than the vacuum or fluid pressure applied to the depressions 20 to achieve higher strength properties such as basis weight, bulk density, thickness, air permeability, and / or opacity for the portion of the web within the depressions 20. The height difference between the depressions 20 and the platform area 18 may be in the range of about 0.1 mm to about 15 mm, about 0.2 mm to about 10 mm, about 0.2 mm to about 5 mm, about 0.3 mm to about 3 mm, about 0.3 mm to about 2 mm, greater than about 0.3 mm, greater than about 0.5 mm, or greater than about 0.8 mm. Having these height differences between the depressions 20 and the plateau regions 18 allows for the formation of a structure with sufficient three-dimensional character to provide visual appeal to the resulting three-dimensional web.

[0035] Figure 8The rotating collection surface 14 is shown to include a plateau region 18 and depressions 20. The bottom portion 26 of the depressions 20 is indicated by a dashed line, indicating that it is fluid permeable. When a vacuum is applied to the bottom portion 26, the filaments may accumulate in greater quantities in the depressions 20 than in the plateau region 18, as described above. Figure 7 As displayed. Figure 7 and Figure 8 The primary difference between the rotating collection surface of the web and the web is the addition of pins 30, which are located on or extend outward from the platform area 18. The height of the pins 30 relative to the platform area 18 can be from about 0.4 mm to about 20 mm, from about 0.4 mm to about 15 mm, from about 0.5 mm to about 10 mm, from about 0.5 mm to about 8 mm, or from about 0.6 mm to about 6 mm. The diameter or major dimension of the pins 30 closest to the outer surface 24 (if not circular) can range from about 0.4 mm to about 15 mm, from about 0.5 mm to about 10 mm, from about 1 mm to about 8 mm, or from about 1 mm to about 6 mm. The pins 30 can be used to create openings in a portion of the web formed on the platform area 18. A vacuum can be provided by the platform area 18 and / or the pins 30, but the vacuum force may be lower than the vacuum force provided in the recesses 20 to achieve a higher filament concentration in the recesses 20. Pins identical or similar to pins 30 may also be positioned in depressions 20 to create openings in the portion of the mesh formed in depressions 20. The height differences between depressions 20 and platform areas 18, and between platform areas 18 and pins 30, may range from about 0.1 mm to about 15 mm, about 0.2 mm to about 10 mm, about 0.2 mm to about 5 mm, about 0.3 mm to about 3 mm, about 0.3 mm to about 2 mm, greater than about 0.3 mm, greater than about 0.5 mm, or greater than about 0.8 mm. These height differences between depressions 20 and platform areas 18, and between platform areas 18 and pins 30, enable the formation of a structure having sufficient three-dimensional features, thereby making the resulting three-dimensional mesh visually appealing.

[0036] Figure 9 The rotating collection surface 14 is shown to include a plateau region 18 and depressions 20. The bottom portion 26 of the depressions 20 is indicated by a dashed line, indicating that it is fluid permeable. When a vacuum is applied to the bottom portion 26, the filaments may accumulate in greater quantities in the depressions 20 than in the plateau region 18, as described above. Figure 7 As shown. Figure 9In the embodiment of the present invention, pins 30 are shown as being located in depressions 20. Pins 30 can create openings in the portion of the web formed in depressions 20. The portion of the web formed on platform area 18 can be planar. Some vacuum can be provided by pins 30 as needed. Vacuum can also be provided by platform area 18, but the vacuum force may be lower than the vacuum force provided in depressions 20 to achieve a higher concentration of filaments in depressions 20. Pins identical or similar to pins 30 can also be provided in platform area 18 to create openings in the portion of the web formed on platform area 18. The height difference between depressions 20 and platform area 18 or pins 30 can be in the range of about 0.1 mm to about 15 mm, about 0.2 mm to about 10 mm, about 0.2 mm to about 5 mm, about 0.3 mm to about 3 mm, about 0.3 mm to about 2 mm, greater than about 0.3 mm, greater than about 0.5 mm, or greater than about 0.8 mm. Having these height differences between the depressions 20 and the land areas 18 or pins 30 allows for the formation of a structure with sufficient three-dimensional character to provide visual appeal to the resulting three-dimensional mesh.

[0037] Figure 10 The rotating collection surface 14 is shown to include a plateau region 18 and depressions 20. The bottom portion 26 of the depressions 20 is indicated by a dashed line, indicating that it is fluid permeable. When a vacuum is applied to the bottom portion 26, the filaments may accumulate in greater quantities in the depressions 20 than in the plateau region 18, as described above. Figure 7 As shown. Figure 10 In the embodiment of the present invention, the platform region 18 includes raised regions 22 that form protrusions in the portion of the web formed by the platform region 18. In some cases, a vacuum can be provided through the raised regions 22 and / or the platform region 18, but the vacuum intensity can generally be lower than the vacuum provided in the recesses 20 to achieve a higher concentration of filaments in the recesses 20. The height difference between the recesses 20 and the platform region 18, as well as the height difference between the platform region 18 and the raised regions 22, can range from about 0.1 mm to about 15 mm, about 0.2 mm to about 10 mm, about 0.2 mm to about 5 mm, about 0.3 mm to about 3 mm, about 0.3 mm to about 2 mm, greater than about 0.3 mm, greater than about 0.5 mm, or greater than about 0.8 mm. These height differences between the recesses 20 and the platform region 18, and between the platform region 18 and the raised regions 22, enable the formation of a structure with sufficient three-dimensional characteristics, thereby making the final three-dimensional web visually appealing.

[0038] Figure 11A rotating collection surface 14 is shown having a fluid-permeable outer surface 32. The outer surface 32 may or may not include raised areas 22. If raised areas 22 are not provided, the vacuum within the rotating collection surface 14 can be varied to create vacuum regions 34 and no / low vacuum regions 36. Filaments may be more attracted to the vacuum regions 34 than to the no / low vacuum regions 36. As a result, the portion of the web formed in the vacuum regions 34 may have higher strength properties than the portion of the web formed in the no / low vacuum regions 36. The strength properties may be basis weight, bulk density, thickness, air permeability, and / or opacity.

[0039] If raised areas 22 are provided on outer surface 32, vacuum regions 36 and no-vacuum / low-vacuum regions 36 may or may not be provided. In the absence of regions 34 / 36, the vacuum force applied to the filaments may be blocked in the area below the raised areas 22. This may cause the filaments to accumulate in locations where vacuum is provided, i.e., between the raised areas 22. As a result, the portion of the web formed between the raised areas 22 may have higher strength characteristics than the portion of the web formed on the raised areas 22. In some cases, a vacuum may be provided by the raised areas 22, but the strength of the vacuum may generally be lower than the vacuum provided between the raised areas 22, in order to achieve a higher concentration of filaments between the raised areas 22. The height difference between the land areas 18 and the raised areas 22 can be in the range of about 0.1 mm to about 15 mm, about 0.2 mm to about 10 mm, about 0.2 mm to about 5 mm, about 0.3 mm to about 3 mm, about 0.3 mm to about 2 mm, greater than about 0.3 mm, greater than about 0.5 mm, or greater than about 0.8 mm. These height differences between the land areas 18 and the raised areas 22 enable the formation of a structure having sufficient three-dimensional features, thereby making the final three-dimensional mesh visually appealing.

[0040] Figure 12A rotating collection surface 14 is shown having a fluid-permeable outer surface 32. Pins 30 extend outwardly from the fluid-permeable outer surface 32. The vacuum force applied to the filaments may be blocked in the area below the pins 30. This may cause the filaments to accumulate at the location where the vacuum is provided, i.e., between the pins 30. As a result, the portion of the web formed between the pins 30 may have higher strength properties than the portion of the web formed on the pins 30. In some cases, a vacuum may be provided by the pins 30, but the strength of the vacuum may generally be lower than the vacuum provided between the pins 30 to achieve a higher concentration of filaments between the pins 30. In some cases, the pins 30 may be used to create openings in the web. The height difference between the platform area 18 and the pins 30 can be in the range of about 0.1 mm to about 15 mm, about 0.2 mm to about 10 mm, about 0.2 mm to about 5 mm, about 0.3 mm to about 3 mm, about 0.3 mm to about 2 mm, greater than about 0.3 mm, greater than about 0.5 mm, or greater than about 0.8 mm. These height differences between the platform area 18 and the pins 30 enable the formation of a structure with sufficient three-dimensional features, thereby making the final three-dimensional network visually appealing.

[0041] Any of the platform areas, pins, raised areas, and / or recesses discussed herein may have at least one dimension of length or width ranging from, for example, about 0.1 mm to about 15 mm, about 0.1 mm to about 10 mm, about 0.3 mm to about 10 mm, about 0.5 mm to about 8 mm, about 0.8 mm to about 5 mm, about 0.8 mm to about 3 mm, about 0.8 mm to about 2 mm, or about 0.8 mm to about 1.2 mm. This allows for the creation of substantial three-dimensional structural properties in the resulting three-dimensional mesh due to the configuration of the platform areas, pins, raised areas, and / or recesses.

[0042] See also Figure 13 , provides a method for making a three-dimensional web. The method may include spinning continuous filaments 28 from a spinneret 52 and then guiding the spun continuous filaments 28 to move or stretch along a travel path 54 having a terminal guide section 56. The method may include rotating a collection surface 14 at or near the terminal guide section 56 of the travel path 54. The rotating collection surface 14 may include a depression 20 and a platform area 18 (such as Figures 5 to 10). The platform region 18 can be tangentially coplanar with the outer surface of the collection surface 14. The recess 20 can be recessed relative to the outer surface of the rotating collection surface 14. The method can include applying fluid pressure (such as a vacuum) to the rotating collection surface 14. The fluid pressure can be applied to all or only a portion of the contact area between the rotating collection surface and the filaments 28 on the rotating collection surface 14. The method can include collecting the filaments 28 on the collection surface 14 to produce an intermediate three-dimensional web 60 having a first region formed in the recess 20 and a second region formed on the platform region 18. The first and second regions can differ in at least one strength characteristic, wherein the strength characteristic is basis weight, bulk density, thickness, air permeability, and / or opacity. The method can include bonding the intermediate three-dimensional web 60 using a bonding process 62 to form a final three-dimensional web 63. Alternatively, the method can include conveying the intermediate three-dimensional web 60 through the bonding process 62 to form the final three-dimensional web 63. The bonding process 62 may include calendering, ultrasonic bonding, through-air bonding, or a combination thereof. In the case of through-air bonding, the method may include generating inter-filament bonds in the intermediate three-dimensional web 60 to form a final three-dimensional web 63 .

[0043] In some cases, the collection surface 14 may be formed in a recess 20 ( Figure 9 ) or in platform area 18 ( Figure 8 and Figure 10 ) include raised areas 22 or pins 30. Raised areas 22 or pins 30 can have any suitable shape, such as pin-shaped, protruding and / or cylindrical. Raised areas 22 or pins 30 can be used to form perforations or protrusions (such as three-dimensional elements) in the middle three-dimensional web 60. The bottom portion of the depression 20 can be fluid-permeable but is not substantially or completely permeable to the long filaments 28. Some long filaments 28 may be able to partially extend through the bottom portion 26 of the depression 20, but generally, complete long filaments 28 may not be able to move through the bottom portion 26. The method can include accumulating long filaments 28 in the depression 20.

[0044] When long filament 28 advances along path of travel 54, the method may include cooling and stretching long filament 28. Long filament 28 may comprise single component fiber, bicomponent fiber or multicomponent fiber. For example, bicomponent fiber may comprise parallel fiber, core-sheath fiber, eccentric fiber or island-in-the-sea fiber. Bicomponent fiber may have a first component comprising a first material, and a second component comprising a second different material. The first material may have a first melting temperature, and the second component may have a second melting temperature. The first melting temperature and the second melting temperature may differ by at least 10 degrees Celsius, but are less than 180 degrees Celsius. This difference in melting temperature causes the filament to curl, which is due to the different cooling rates of different components. Curling may contribute to providing bulk for the web.

[0045] As mentioned above, the rotating collection surface 14 can be a rotating member or drum, which may or may not be circular. The rotating member or drum can have a textured outer surface that is at least partially permeable to the fluid. In other cases, the rotating collection surface can be a rotating member or drum having a three-dimensional sleeve disposed thereover.

[0046] See again Figure 13 The method may include compacting the intermediate three-dimensional web 60 using one or more compacting rollers 66. The compacting rollers 66 may form a nip with the rotating collection surface 14 through which the intermediate three-dimensional web may be conveyed. Downstream of the nip, or after leaving the nip, the three-dimensional web may be peeled from the rotating collection surface and conveyed onto a conveyor belt. The web may be peeled from the rotating collection surface and conveyed to a position that is substantially the same as the web of the embodiment of FIG. Figure 13 In other words, the web can be detached or peeled from the rotating collection surface and Figure 13 The rotating collection surface can rotate in either direction and, likewise, the web can be conveyed to the left or to the right. The compacting roller 66 can be positioned on one side or the other of the rotating collection surface, based on the side through which the web is intended to travel. The compacting roller 66 can have a smooth surface, or can be textured to complement the texture on the rotating collection surface 14, or to form a concave-convex mating structure corresponding to the rotating collection surface, as will be discussed in further detail below. The one or more compacting rollers 66 can be heated to a temperature in the range of about 50 degrees Celsius to about 200 degrees Celsius. The one or more compacting rollers 66 can provide a pressure within a certain range to the web. In some cases, a hot air knife can be used in place of or in conjunction with one or more compacting rollers 66, at the location of the compacting roller 66 and / or at other locations.

[0047] In other cases, it may be desirable to use a hot air knife 68 or other energy source downstream of the compacting roller 66 to apply hot air to the intermediate three-dimensional web 60 to achieve at least partial bonding of the intermediate three-dimensional web 60. The hot air knife 68 can be positioned anywhere between the rotating collection surface 14 and the bonding process 62. The hot air knife or other energy source can also be positioned near or directed toward the rotating collection surface 14 to enhance the compaction of the web on the rotating collection surface. For example, the hot air knife can provide hot air at a temperature in the range of about 120 degrees Celsius to about 300 degrees Celsius or about 140 degrees Celsius to about 200 degrees Celsius.

[0048] The method may include delivering the final three-dimensional web 63 to an absorbent product production line 70. In other cases, the method may be performed as part of an absorbent product production line. The method may include using a diffuser 51 to disperse the filaments 28 along the travel path 54. The final three-dimensional web 63 may not be hydroentangled, or may not be hydroentangled.

[0049] In any of the various forms described herein, the formed web can be combined with a pre-bonded or non-pre-bonded web to increase the basis weight of the web or to form a laminate. If desired, this can be done on the same production line where the web is formed.

[0050] The longitudinal length of the filaments laid on the rotating collection surface of the present disclosure may be less than 25%, less than 15%, or less than 13% of the circumference or outer surface perimeter of the rotating collection surface, but at least 2% or 5% of the latter. The transverse width of the filaments laid on the rotating collection surface of the present disclosure may be greater than 20 mm and less than 400 mm.

[0051] See also Figure 14 , the method may include additional steps, such as providing a second rotating collection surface 72, and providing a meltblowing die head or slurry source 74. Figure 14 Zhongyu Figure 13Elements with the same number indicate that the elements are identical or similar. The second rotating collection surface 72 can be identical or similar to the rotating collection surface 14, or it can simply be a non-textured collection surface. Thus, the second rotating collection surface 72 can produce a web 76 with variable strength properties (such as basis weight) similar to those described above for the collection surface 14, or the second rotating collection surface 72 can simply produce a web 76 without variable strength properties to increase the basis weight of the intermediate three-dimensional web 60. If the second rotating collection surface 72 produces a web 76 with variable strength properties, the web 76 can be positionally laminated with the intermediate three-dimensional web 60 or not. The web 76 can be combined with the intermediate three-dimensional web 60 to form a laminate 58. The second rotating collection surface 72 can produce a web 76 with variable strength properties that are the same as or different from the variable strength properties of the intermediate three-dimensional web 60 produced by the rotating collection surface 14. In this case, the web 60 can have the same or different pattern as the web 76. This can be accomplished by configuring the rotating collection surface 14 with a different texture than the second rotating collection surface 72, or by using different textured sleeves on the rotating collection surfaces 14, 72. Any of the webs described herein having variable strength properties can have one pattern or area (e.g., a wallpaper pattern), or more than one pattern or area.

[0052] The method may include, after the collecting step and before the bonding step, spinning second continuous filaments 78 from a second spinneret 80 and collecting the second continuous filaments 78 on the intermediate three-dimensional web 60 to increase the basis weight of the intermediate three-dimensional web 60 .

[0053] The method may include providing slurry fibers, staple fibers, and / or meltblown fibers 82 to the intermediate three-dimensional web 60. The slurry fibers, staple fibers, and / or meltblown fibers 82 may be provided to the rotating collection surface 14 and / or the second rotating collection surface 72 using a meltblowing die or slurry source 74. Thus, the intermediate three-dimensional web 60 may include slurry fibers, staple fibers, and / or meltblown fibers 82. A compacting roller 66 may also be positioned adjacent to the rotating collection surface 14 and / or the second rotating collection surface 72 to compact the web prior to the bonding process 62.

[0054] The method of making a three-dimensional web may include spinning continuous filaments 28 from a spinneret 52 and then directing the spun continuous filaments 28 along a travel path 56 having a terminal guide section 56. The method may include rotating a collection surface 14 at or near the terminal guide section 56 of the travel path 54, wherein the collection surface 14 may include a planar region 18 and a raised region 22 (see, e.g., Figure 11 and Figure 12), wherein the platform region 18 is tangentially coplanar with the outer surface 32 of the collection surface 14, wherein the raised regions 22 extend outwardly from the outer surface 32 of the collection surface 14, and wherein the platform region 18 has a higher fluid permeability than the raised regions 22. The method may include applying fluid pressure (such as a vacuum) to the collection surface 14. The method may include collecting the filaments 28 on the collection surface 14 to produce an intermediate three-dimensional web 60, the intermediate three-dimensional web having a first region formed on the platform region 18 and a second region formed on the raised regions 22, wherein the first region and the second region may differ in at least one strength characteristic. The strength characteristic may be basis weight, bulk density, thickness, air permeability and / or opacity. The method may include bonding the intermediate three-dimensional web 60 using a bonding process 62 to form a final three-dimensional web 63. Alternatively, the method may include conveying the intermediate three-dimensional web 60 through a bonding process 62 to form a final three-dimensional web 63.

[0055] The method may include providing a depression 20 that is recessed relative to the outer surface 32 of the collection surface 14, wherein a bottom portion 26 of the depression 20 is fluid permeable but substantially impermeable to the filaments 20. The raised areas 22 may be continuous and the plateau areas 18 may be discrete. Alternatively, the plateau areas 18 may be continuous and the raised areas 22 may be discrete.

[0056] The bonding process 62 may include through-air bonding, calendering bonding, ultrasonic bonding, or other suitable bonding techniques, such as mechanical bonding.

[0057] The collection surface 14 may comprise a three-dimensional sleeve 10 that is positioned over a rotating member or drum 12. The method may be performed on an absorbent article production line 70, or the final three-dimensional web 63 may be fed into an absorbent article production line 70.

[0058] Instead of or in conjunction with the compaction roller 66, the auxiliary roller 86 can be set Figure 14 The position of the compacting roller 66 is shown in FIG. Figure 15 is an example of the auxiliary roller 86 engaging a portion of the rotating collection surface 14 of the present disclosure. Figure 16 is an example of the auxiliary roller 86 engaging a portion of the rotating collection surface 14 of the present disclosure. Figure 15A rotating collection surface 14 having raised areas 22 or pins 30 and an auxiliary roller having recesses 20' are shown. The method may include positioning an auxiliary roller 86 adjacent the rotating collection surface 14, wherein the auxiliary roller includes the recesses 20'. The method may include rotating the auxiliary roller 86 with the rotating collection surface 14 and engaging the raised areas 22 or pins 30 of the rotating collection surface 14 into the recesses 20' of the auxiliary roller 86. This process will allow for the formation of clear openings because: (1) areas of the rotating collection surface 14 where the raised areas 22 or pins 30 are not provided form areas of higher basis weight, while areas of the raised areas 22 or pins 30 form areas of lower basis weight or partially formed openings (see, e.g., Figure 12 ), and (2) the mesh is further formed or directly formed into openings through the mechanical meshing action of the male and female molds.

[0059] Figure 16 A rotating collection surface 14 having depressions 20 and an auxiliary roller 86 having raised areas 22' or pins 30' are shown. The method may include positioning the auxiliary roller 86 adjacent the rotating collection surface 14, wherein the auxiliary roller has raised areas 22' or pins 30'. The method may include rotating the auxiliary roller 86 with the rotating collection surface 14 and engaging the raised areas 22' or pins 30' of the auxiliary roller 86 into the depressions 20 of the rotating collection surface 14 to create protrusions or openings. This process will allow for the formation of clear openings because: (1) areas of the rotating collection surface 14 where the raised areas 22 or pins 30 are not provided form areas of higher basis weight, while areas of the raised areas 22 or pins 30 form areas of lower basis weight or partially formed openings (see, e.g., Figure 12 ), and (2) the mesh is further formed or directly formed into openings through the mechanical meshing action of the male and female molds.

[0060] The method may include a web release step or a web blow-off step. For example, fluid pressure may contact the web downstream of the laying position on the rotating collection surface to release the web at least partially or completely from the rotating collection surface. This may be achieved by providing fluid pressure outward from the inside of the rotating collection surface. This may also be achieved by using a vacuum, such as by sucking the web substantially away from the rotating collection surface by a vacuum roller. In some cases, the fluid pressure applied outward from the inside of the rotating collection surface may be used in combination with a vacuum to achieve optimized release of the web from the rotating collection surface. Due to the complexity of the three-dimensional feature pattern formed by the method disclosed herein, releasing the web may be an appropriate step to achieve full formation of the web. For example, during rotation of the rotating collection surface, the web release step may be carried out downstream of a compacting roller or an auxiliary roller.

[0061] In addition to applying fluid pressure and / or vacuum from the interior of the rotating collection surface to release the web, the rotating collection surface can also be cleaned using the same or similar process. Given the complex pattern formed by the rotating collection surface, some filaments or portions thereof may become trapped or entangled in permeable areas or other areas of the rotating collection surface. Cleaning the rotating collection surface can be an important step to achieve a suitable run time. For example, the cleaning step can be performed downstream of the compaction roller or auxiliary roller while the rotating collection surface is rotating.

[0062] The rotating collection surface of the present disclosure can be used to produce a nonwoven fabric or three-dimensional web comprising a first surface and a second surface, and a pattern of visually discernible three-dimensional features on one of the first surface or the second surface. Each of these three-dimensional features can define a micro-region comprising a first region and a second region. The first region and the second region can have a difference in the value of an intensity characteristic, wherein the intensity characteristic can be one, two, or all three of thickness, basis weight, and bulk density. Such nonwoven fabrics are described in the following patents: PCT Publication WO 2017 / 105997, U.S. Patent Application Publication No. US 2018 / 0168893, U.S. Patent Application Publication No. US 2018 / 0216271, U.S. Patent Application Publication No. US 2018 / 0214318, U.S. Patent Application Publication No. US 2020 / 0268572, U.S. Patent Application Publication No. US 2020 / 0299880, and U.S. Patent Application Publication No. US 2021 / 0369511.

[0063] The rotating collection surface of the present disclosure can have the following dimensions. The major dimension (in either direction) of the platform area 18 with low fluid permeability (or no fluid permeability) can be between about 0.1 mm and about 100 mm. The recess 20 with higher fluid permeability can have an opening (so as to be fluid permeable) with a major dimension ranging from about 0.1 mm to about 4 mm, or between about 0.2 mm and about 1.5 mm (for example, in the case of a circular opening, its diameter can be between about 0.1 mm and about 4 mm, or between about 0.2 mm and about 1.5 mm). The major dimension of the recess 20 can be between about 0.1 mm and about 100 mm in either direction. The percentage of the fluid permeable area of ​​the rotating collection surface or the three-dimensional sleeve to the total surface area of ​​the rotating collection surface or the total surface area of ​​the three-dimensional sleeve can be in the range of about 5% to about 95%, about 20% to about 80%, or about 40% to about 70%. The setting of these selected fluid permeable area ranges is intended to ensure that sufficient differential fluid flow is formed between different areas, thereby prompting different filaments to move into different areas. For spun filaments with an average filament diameter of 10 microns to 40 microns (equivalent to 0.7 to 6 denier filaments), at least one dimension of the depression can be >1mm, >2mm or >3mm. This dimension should be set along the longitudinal direction of movement. The spinning density of the spinneret can be at least about 15 filaments / cm, and the output of each spinning position can be at least about 30 filaments. The longitudinal width of the spinning beam should be at least 15mm and can be in the range of about 25mm to about 60mm. The total basis weight of the web can be at least 12gsm and up to about 150gsm or 100gsm. The above design standards can ensure sufficient resolution accuracy during web manufacturing, so that the formed web can obtain high-definition texture features and uniform structural properties.

[0064] If a circular rotating collection surface or a three-dimensional sleeve is used, the diameter may be from about 300 mm to about 10 m. If a non-circular rotating collection surface or a three-dimensional sleeve is used, the circumference may be in the range of from about 1 m to about 100 m.

[0065] The filaments can have any suitable composition and can be monocomponent filaments or bicomponent filaments. Example polymers can include polypropylene, polyethylene, polar solvent soluble materials, non-polar solvent soluble materials, polyvinyl alcohol, water-soluble starch, water-soluble hydroxyl polymers, polysaccharides, or combinations thereof. The filaments can also include recycled materials and / or bio-based materials. The filaments can also include slurry.

[0066] Long filament can have any suitable composition, and can be monocomponent long filament or bicomponent long filament.Example polymer for long filament can comprise polypropylene, polyethylene, polyolefin, polyester, PLA, polar solvent soluble material, non-polar solvent soluble material, polyvinyl alcohol, water-soluble starch, water-soluble hydroxy polymer, polysaccharide, cellulose, cellulose derivative, or their combination.Long filament can also comprise recycled material and / or bio-based material.The polymeric material of example can also comprise those described in following patent: U.S. Patent Application Publication No. US2013 / 0171421, U.S. Patent Application Publication No. 2012 / 0052037, and U.S. Patent Application Publication No. 2015 / 0071572.Other example polymeric material comprising cellulose or cellulose derivative can comprise those described in following patent: U.S. Patent Application Publication No. US 2023 / 0098304, and U.S. Patent No. US 11,326,283.Bicomponent long filament can be crimped. Crimping of bicomponent fibers can occur through differential cooling rates of the first component and the second component.

[0067] The three-dimensional webs formed using the methods described herein may also comprise a blend of filaments, fibrillated fibers, and / or particles, so-called coform webs. For example, fibrillated fibers include wood pulp fibers, cellulose fibers, cellulose fiber derivative fibers, staple fibers, plant-based fibers, bamboo fibers, and combinations thereof. Example three-dimensional webs comprising filaments and particles include those described in U.S. Patent Application Publication No. 2013-2013. No. 0172226, U.S. Patent Application Publication No. 2009 / 0233072, U.S. Patent Application Publication No. 2015 / 0071572, U.S. Patent Application Publication No. 2017 / 0165720, WO2020 / 147227, WO2020 / 147228, WO2020 / 147229, WO2020 / 147230, WO2020 / 147231, WO2020 / 147232, U.S. Patent No. 8,017,534, U.S. Patent No. 8,852,474, U.S. Patent No. 10,513,801, U.S. Patent No. 11,326,276, and U.S. Patent Application Publication No. 2022 / 0325440.

[0068] In some cases, two spinnerets can deposit filaments onto a single rotating collecting surface at different locations on the surface. This process can reduce or eliminate the need for positioning and compounding between two sets of three-dimensional webs produced on different rotating collecting surfaces. This process can also increase production output and production line speed, thereby reducing material costs. Compared to using two independent rotating collecting surfaces (using a spinneret to deposit filaments onto each rotating collecting surface), using two spinnerets to deposit filaments onto a single rotating collecting surface at different locations on the surface can deliver improved three-dimensional patterning results.

[0069] See also Figure 17 , a first spinneret 100 can deposit a first filament 102 onto a first position 104 on a single rotating collection surface 114, and a second spinneret 106 can deposit a second filament 108 onto a second, different position 110 on the single rotating collection surface 114. The second filament 108 can be deposited onto the first filament 102. A compacting roller 166 similar to the compacting roller 66 described herein can also be provided. Alternatively, an auxiliary roller similar to the auxiliary roller 86 described herein can be provided. The remaining steps of the web manufacturing process can be similar to the process described herein.

[0070] See also Figure 18, showing a schematic example of a rotating collection surface 214. The rotating collection surface 214 includes an outer three-dimensional sleeve 210, a porous member 200 and a support screen 202. The support screen 202 can provide structural integrity for the three-dimensional sleeve 10, such as when a force is applied to the three-dimensional sleeve 210 using a compacting roller 66 or an auxiliary roller 86. The support screen 202 typically has a larger opening ratio, such as in the range of about 25% to about 60%, and can have a thickness in the range of, for example, about 0.2mm to about 6mm. Since the opening ratio of the support screen is not typically, for example, 75% to 95%, a porous member 200 can be provided between the three-dimensional sleeve 210 and the support screen 202 to provide uniform fluid pressure to the three-dimensional sleeve 210. The porous member 200 can also provide a gap between the three-dimensional sleeve 210 and the support screen 202 to again provide uniform fluid pressure to the three-dimensional sleeve 210. Fluid conduit 204 can provide fluid pressure to support screen 202, and finally provides fluid pressure to three-dimensional sleeve 210.Any one in fluid conduit 204 all can open or close, or has the fluid flow of increase or the fluid flow of reduction.In one example, when the part of mesh is present in this part above three-dimensional sleeve 210, fluid conduit 204 can be opened.In another example, more fluid pressure can be provided to three-dimensional sleeve 210 in the long filament laying area.As mentioned herein, fluid conduit 204 can be configured to send positive fluid pressure and / or negative fluid pressure.Negative fluid pressure can be used for long filament and / or mesh being drawn in three-dimensional screen 210, and positive fluid pressure can be used for discharging mesh from rotation collection surface 210, or can be used for discharging part or complete long filament that is caught or wound in three-dimensional sleeve, thereby three-dimensional sleeve is cleaned.

[0071] See also Figure 19 , showing another schematic example of a rotating collection surface 314. Except that the porous member may not be provided, the rotating collection surface 314 is similar to Figure 18 The rotating collection surface 314 may be the same as the rotating collection surface 214. The rotating collection surface 314 may include a three-dimensional sleeve 310, a support member 302, and a fluid conduit 304.

[0072] The air permeability of various support screens can be around 45m 3 / m 2 / min to about 400m 3 / m 2 / min, about 60m 3 / m 2 / min to about 350m 3 / m 2 / min or about 75m 3 / m 2 / min to about 300m 3 / m 2The support screen of the present disclosure may have a circular pattern of hollow materials to achieve fluid permeability. Other shapes of hollow materials may also be used, such as oval, elongated, and / or slotted.

[0073] The air permeability of the porous member can be about 45m 3 / m 2 / min to about 400m 3 / m 2 / min, about 60m 3 / m 2 / min to about 350m 3 / m 2 / min or about 75m 3 / m 2 / min to about 300m 3 / m 2 / min range.

[0074] The three-dimensional sleeve may comprise a polymer material such as polyoxymethylene, or may comprise a metallic material such as steel, nickel and / or brass. Other suitable materials may also be used.

[0075] The porous member may comprise a metallic material (such as steel) or a polymeric material. Other suitable materials may also be used.

[0076] The support screen may comprise a metal material such as steel. Other suitable materials may also be used.

[0077] The speed that method discussed herein uses a single spinneret to produce a web can be from about 40 meters per minute to about 300 meters per minute. The speed that method discussed herein uses two spinnerets to produce a web can be from about 80 meters per minute to about 600 meters per minute. The speed that method discussed herein uses three spinnerets to produce a web can be from about 120 meters per minute to about 1200 meters per minute.

[0078] Surface morphology

[0079] The rotating collection surface disclosed herein may have a specific surface texture (Sa, arithmetic mean height) in the following areas: the flat areas, the surface of the raised areas, the protrusions or pins, and / or the bottom and / or sidewalls of the recesses. Having a specific range of surface texture (Sa) in the flat areas, the surface of the raised areas, the protrusions or pins, and / or the bottom and / or sidewalls of the recesses helps facilitate the release of the filaments from the rotating collection surface after web formation. In one example, the specific surface texture can be present anywhere the filaments contact the rotating collection surface. For example, the surface texture (Sa) can range from about 10µm to about 220µm, about 10µm to about 200µm, about 10µm to about 150µm, about 10µm to about 100µm, or about 15µm to about 100µm. Surface texture (Sa) is measured using the "Surface Topography Test Method" described herein. In one example, in the plateau region, the surface texture (Sa) can be in the range of about 10µm to about 220µm, about 10µm to about 200µm, about 10µm to about 150µm, about 10µm to about 100µm, or about 15µm to about 100µm. The surface texture (Sa) is measured using the "Surface Topography Test Method" herein.

[0080] Surface morphology testing methods

[0081] In surface topography testing, optical profilometry is used to measure the regional surface topology of a sample's surface. The three-dimensional (3D) surface data is then processed and analyzed to extract the microscale regional surface texture parameter Sa (arithmetic mean height). Sa is the average of the absolute height values ​​of each point within a defined area.

[0082] The high-brightness LED light source in the projection unit of the Keyence VR-6000 / 6200 3D optical profiler is used to acquire 3D surface topography images of the conveyor belt. This system consists of the following main components: a) the controller (VR-6000), which houses the high-brightness LED light source for observation, a control circuit board, and other hardware; and b) the measurement head, which includes the high-brightness LED light source for measurement, a CMOS camera, scanning optics, and a telecentric lens. The fringe projection light source is refracted by the telecentric projection lens and projected obliquely from above onto the object being measured. When there are height differences on the surface of the object being measured and the light is projected obliquely onto the object, the fringe projection image will be distorted. The VR-6000 series uses a camera to capture this distorted fringe projection image and infers the object's height based on the amount of distortion.

[0083] Under ambient conditions, the sample was placed flat on a motorized stage below the camera. A counterweight was applied outside the sample measurement area to eliminate large-scale waviness of the sample. The four images were stitched together to form a three-dimensional surface topology image of the sample surface (approximately 30 mm × 40 mm). Before measurement, the image was pre-processed according to the instrument manufacturer's recommended procedures to correct surface shape errors and reduce noise. Within the filtered height image, a region of interest containing the three-dimensional features of the rotationally collected surface described in this disclosure was selected, and Sa was measured according to ISO 25178-2:2012.

[0084] Example / Combination :

[0085] 1. A method for making a three-dimensional mesh, comprising:

[0086] Spinning continuous filaments from a spinneret;

[0087] guiding the spun continuous filaments to move along a travel path having a terminal guide section;

[0088] rotating a collection surface at or near the terminal guide section of the travel path, wherein the collection surface includes a plateau region and a raised region, wherein the plateau region is tangentially coplanar with an outer surface of the collection surface, wherein the raised region extends outwardly from the outer surface of the collection surface, and wherein the plateau region has a higher fluid permeability than the raised region;

[0089] applying fluid pressure to the collection surface;

[0090] collecting the filaments on the collection surface to produce an intermediate three-dimensional network having first regions formed on the land areas and second regions formed on the raised areas, wherein the first and second regions differ in at least one strength characteristic; and

[0091] A bonding process is used to bond the intermediate three-dimensional network to form a final three-dimensional network.

[0092] 2. The method of paragraph 1, comprising providing a depression recessed relative to the outer surface of the collection surface, and generating fluid pressure at a bottom of the depression, the bottom being fluid permeable but substantially non-filament permeable.

[0093] 3. The method of paragraph 1 or 2, wherein the raised regions are continuous, and wherein the plateau regions are discrete.

[0094] 4. The method of paragraph 1 or 2, wherein the plateau region is continuous, and wherein the raised regions are discrete.

[0095] 5. The method according to any one of paragraphs 1 to 4, wherein the bonding process comprises through-air bonding, calendering bonding, ultrasonic bonding, or a combination thereof.

[0096] 6. The method of any of paragraphs 1 to 5, wherein the collection surface comprises a three-dimensional sleeve disposed over the rotating member.

[0097] 7. The method of any of paragraphs 1 to 6, wherein the method is performed on an absorbent article production line.

[0098] 8. The method according to any one of paragraphs 1 to 7, comprising:

[0099] disposing an auxiliary roller adjacent to the rotating collection surface, wherein the auxiliary roller includes a depression;

[0100] rotating the auxiliary roller together with the rotating collection surface; and

[0101] The raised areas of the rotating collecting surface engage into the recesses of the auxiliary roller.

[0102] 9. The method of paragraph 2, comprising:

[0103] disposing an auxiliary roller adjacent to the rotating collection surface, wherein the auxiliary roller has a raised area;

[0104] rotating the auxiliary roller together with the rotating collection surface;

[0105] The second raised area of ​​the auxiliary roller engages into the recess of the rotating collecting surface to create a protrusion or opening.

[0106] 10. The method of paragraph 1, comprising using the raised regions to form openings in the intermediate three-dimensional network.

[0107] 11. The method of any of paragraphs 1 to 10, wherein the filament comprises polypropylene, polyethylene, polyester, PLA, a polar solvent soluble material, a non-polar solvent soluble material, polyvinyl alcohol, a water-soluble starch, a water-soluble hydroxyl polymer, a polysaccharide, or a combination thereof.

[0108] 12. The method of any of paragraphs 1 to 11, wherein the three-dimensional network comprises the filaments, monofilaments and / or particles.

[0109] 13. The method of any of paragraphs 1 to 12, wherein the platform region of a portion of the rotating collection surface has a surface texture Sa in the range of about 10 μm to about 220 μm according to the Surface Topography Test Method.

[0110] 14. A method for making a three-dimensional mesh, comprising:

[0111] spinning a first continuous filament from a first spinneret;

[0112] guiding the spun first continuous filament to move along a first travel path having a first terminal guide section;

[0113] spinning a second continuous filament from a second spinneret;

[0114] guiding the spun second continuous filaments to move along a second travel path having a second terminal guide section;

[0115] rotating a single collection surface at or near the first terminal guide section of the first travel path and at or near the second terminal guide section of the second travel path, wherein the collection surface includes a depression and a plateau region, wherein the plateau region is tangentially coplanar with an outer surface of the collection surface, and wherein the depression is recessed relative to the outer surface of the collection surface; and

[0116] applying fluid pressure to the collection surface; and

[0117] collecting the first and second filaments on the collection surface to produce an intermediate three-dimensional network having first regions formed in the recesses and second regions formed on the land areas, wherein the first and second regions differ in at least one strength characteristic, and wherein the strength characteristics of the first and second regions each have a value greater than zero; and

[0118] A bonding process is used to bond the intermediate three-dimensional network to form a final three-dimensional network.

[0119] 15. The method of paragraph 14, wherein the collecting step comprises collecting the second filament on the first filament.

[0120] 16. The method of paragraph 14, wherein the first terminal guide section of the first travel path and the second terminal guide section of the second travel path are located at different locations on a single rotating collection surface.

[0121] 17. The method of any of paragraphs 14 to 16, wherein the platform region of a portion of the single rotating collection surface has a surface texture Sa in the range of about 10 μm to about 220 μm according to the Surface Topography Test Method.

[0122] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0123] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patents or applications, is incorporated herein by reference in its entirety. Citation of any document is not an admission that it is prior art with respect to any embodiment disclosed or claimed herein, or that it alone or in any combination with any other reference or references suggests, suggests, or discloses any such embodiment. In addition, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0124] While specific embodiments of the present disclosure have been illustrated and described, it will be apparent to those skilled in the art that many other changes and modifications may be made without departing from the spirit and scope of the present disclosure. It is therefore intended that all such changes and modifications within the scope of the present disclosure be encompassed in the appended claims.

Claims

1. A method for making a three-dimensional mesh, comprising: Spinning continuous filaments from a spinneret; guiding the spun continuous filaments to move along a travel path having a terminal guide section; rotating a collection surface at or near the terminal guide section of the travel path, wherein the collection surface includes a depression and a plateau region, wherein the plateau region is tangentially coplanar with an outer surface of the collection surface, and wherein the depression is concave relative to the outer surface of the collection surface; as well as applying fluid pressure to the collection surface; as well as collecting the filaments on the collection surface to produce an intermediate three-dimensional network having first regions formed in the recesses and second regions formed on the land areas, wherein the first and second regions differ in at least one strength characteristic, and wherein the strength characteristics of the first and second regions each have a value greater than zero; and A bonding process is used to bond the intermediate three-dimensional network to form a final three-dimensional network.

2. The method of claim 1, wherein the collection surface comprises a raised area extending outwardly from the outer surface of the collection surface.

3. The method of claim 2, comprising using the raised areas to form openings in the intermediate three-dimensional network.

4. The method of claim 2, comprising using the raised regions to form protrusions in the intermediate three-dimensional network.

5. A method according to any one of the preceding claims, comprising generating fluid pressure at a bottom portion of the recess, the bottom portion being fluid permeable but substantially not filament permeable, and comprising accumulating the filaments in the recess.

6. A method according to any preceding claim, comprising cooling and stretching the filaments along the travel path.

7. The method of any one of the preceding claims, wherein the continuous filaments comprise bicomponent continuous filaments having a first component and a second component.

8. The method of claim 7, wherein the bicomponent filaments are side-by-side bicomponent filaments or eccentric bicomponent filaments.

9. The method of claim 7, wherein the first component has a different melting temperature than the second component.

10. A method according to any preceding claim, wherein the collection surface is a rotating drum rather than a conveyor belt.

11. The method of any one of claims 1 to 10, wherein the collection surface comprises a three-dimensional sleeve disposed over a rotating member, wherein the three-dimensional sleeve is not a conveyor belt.

12. A method according to any preceding claim comprising through air bonding the intermediate three-dimensional web to create inter-filament bonds in the web and form the final three-dimensional web.

13. The method according to any one of the preceding claims, comprises compacting the intermediate three-dimensional network onto the collecting surface using a compacting roller, wherein a pressure zone is formed between the compacting roller and the collecting surface, and wherein the intermediate three-dimensional network is peeled off from the collecting surface downstream of the pressure zone or after leaving the pressure zone.

14. A method according to any preceding claim, comprising applying hot air to the intermediate three-dimensional web to achieve at least partial bonding of the intermediate three-dimensional web.

15. A method according to any preceding claim comprising combining a second web with the intermediate three-dimensional web to form a laminate.

16. The method of any of the preceding claims, comprising spinning second continuous filaments from a second spinneret after the collecting step and before the bonding step, and collecting the second continuous filaments on the intermediate three-dimensional web to increase the basis weight of the intermediate three-dimensional web.

17. The method according to any one of claims 1 to 15, comprising spinning second continuous filaments from a second spinneret onto a second collecting surface after the collecting step and before the bonding step, and delivering the second continuous filaments to the intermediate three-dimensional web to increase the basis weight of the intermediate three-dimensional web.

18. A method according to any preceding claim, comprising feeding the final three-dimensional web into an absorbent article production line.

19. A method according to any preceding claim, comprising spreading the filaments along the path of travel.

20. The method of any preceding claim, wherein the strength property is basis weight, thickness, or bulk density.

21. The method of any preceding claim, wherein the intensity property is air permeability or opacity.

22. The method of any one of the preceding claims, wherein the web comprises pulp fibers, or wherein the web comprises staple fibers.

23. The method of any one of the preceding claims, wherein the bonding process comprises calendering bonding, ultrasonic bonding, or a combination thereof.

24. The method according to any one of the preceding claims, wherein the final three-dimensional web has not been hydroentangled.

25. A method according to any preceding claim, wherein the depressions have a higher fluid permeability than the plateau regions.

26. The method according to any one of the preceding claims, wherein the method is performed on an absorbent article production line.

27. The method of any of the preceding claims, wherein the land area of ​​a portion of the rotating collection surface has a surface texture Sa in the range of about 10 μm to about 220 μm according to the Surface Topography Test Method.

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