US 11,788,221 B2
Process for making three-dimensional foam-laid nonwovens
Davis Dang H. Nhan, Menasha, WI (US); Cathleen M. Uttecht, Menasha, WI (US); Lori A. Eslinger, Appleton, WI (US); Neil T. Scholl, Neenah, WI (US); Jian Qin, Appleton, WI (US); Charles W. Colman, Marietta, GA (US); Deborah J. Calewarts, Winneconne, WI (US); Vasily A. Topolkaraev, Appleton, WI (US); and Antonio J. Carrillo Ojeda, Appleton, WI (US)
Filed by KIMBERLY-CLARK WORLDWIDE, INC., Neenah, WI (US)
Filed on Mar. 16, 2022, as Appl. No. 17/696,071.
Application 17/696,071 is a continuation of application No. 17/262,385, granted, now 11,313,061, previously published as PCT/US2018/043662, filed on Jul. 25, 2018.
Prior Publication US 2022/0205154 A1, Jun. 30, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. D04H 1/541 (2012.01); D04H 1/4391 (2012.01); D04H 1/68 (2012.01); D21H 13/10 (2006.01); A61F 13/15 (2006.01); A61F 13/511 (2006.01); D04H 1/76 (2012.01); D21H 21/24 (2006.01)
CPC D04H 1/5412 (2020.05) [A61F 13/15577 (2013.01); A61F 13/51104 (2013.01); D04H 1/43916 (2020.05); D04H 1/68 (2013.01); D04H 1/76 (2013.01); D21H 13/10 (2013.01); D21H 21/24 (2013.01); A61F 2013/15934 (2013.01); A61F 2013/51134 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method for making a high topography nonwoven substrate, the method comprising:
generating a foam including water and synthetic binder fibers;
depositing the foam on a foraminous belt;
disposing a template form on the foam opposite the foraminous belt to create a foam/form assembly;
heating the foam to dry the foam and bind the synthetic binder fibers to form the substrate; and
removing the template from the substrate after heating, wherein the substrate includes a base layer having an X-Y surface and a backside surface opposite the X-Y surface, the base layer having a density; and
a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein each projection element has a height, a diameter or width, a cross-section, a sidewall, a density, a proximal end where the projection element meets the base layer, and a distal end opposite the proximal end, and wherein the density of a projection element is the same as the density of the base layer.