IP Library › Granted Patent US 7,279,198
Granted Patent B1
US 7,279,198 · App. 09/978,524 · Granted Oct 9, 2007

Method for extrusion coating a lightweight web

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Quick Facts
Patent No.
US 7,279,198
App. No.
09/978,524
Granted
Oct 9, 2007
Kind
B1
Abstract

The specification discloses a method for extrusion coating a lightweight web. According to the method, a length of a lightweight web along with a length of a carrier web is fed to an extruder with the lightweight web positioned atop the carrier web. A polymer film is then extruded onto the combined lightweight web and carrier web to provide an extrusion-coated lightweight web. Thereafter, the extrusion-coated lightweight is separated from the carrier web. Also disclosed are extrusion-coated lightweight webs formed according to the method.

Claims (36)

1. A method for extrusion coating a lightweight web comprising:

feeding a length of a nonwoven fabric, lightweight web along with a length of carrier web to an extruder with the lightweight web atop the carrier web;

extruding a polymer film coating onto the lightweight web and carrier web in the extruder so that a surface of the lightweight web is coated by the extruded coating to provide an extrusion-coated lightweight web; and

separating the extrusion-coated lightweight web from the carrier web.

2. The method of claim 1 wherein the lightweight web has a width less than a width of the carrier web and is affixed to the carrier web by the polymer film coating, and wherein a width of the polymer film coating is greater than the width of the lightweight web.

3. The method of claim 1 wherein the lightweight web exhibits deformations when subjected to a tension of about 0.5 pli or less.

4. The method of claim 1 wherein the polymer film coating comprises a polymer selected from the group consisting of low density polyethylene (LDPE), polyolefin plastomers (POP), polyolefin elastomers (POE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), polypropylene (PP), ethylene methyl acrylate copolymer (EMA), ethylene butyl acrylate copolymer (EnBA), ethylene vinyl acetate copolymer (EVA), ethylene acrylic acid copolymer (EAA), ethylene methyl acrylic acid copolymer (EMAA), ionomoers, ethylene vinyl alcohol (EVOH), polyesters such as polyethylene terephthalate (PET), polyamides, and one or more of the foregoing.

5. The method of claim 1 wherein the lightweight web has a MD curl of less than about 3 inches as measured by TAPPI UM 427.

6. The method of claim 1 wherein the lightweight web has insufficient strength properties in the absence of the underlying carrier web to withstand forces imposed upon it in an extruder coating station.

7. The method of claim 1 wherein the carrier web is a heavyweight web.

8. The method of claim 1 wherein the carrier web is a second lightweight web.

9. The method of claim 1 wherein the polymer film coating comprises a coextrusion of at least two layers of polymer films.

10. A method for extrusion coating a lightweight web comprising:

feeding a length of a paper, lightweight web along with a length of carrier web to an extruder with the lightweight web atop the carrier web;

extruding a polymer film coating onto the lightweight web and carrier web in the extruder so that a surface of the lightweight web is coated by the extruded coating to provide an extrusion-coated lightweight web; and

separating the extrusion-coated lightweight web from the carrier web.

11. The method of claim 10 wherein the lightweight web has a width less than a width of the carrier web and is affixed to the carrier web by the polymer film coating, and wherein a width of the polymer film coating is greater than the width of the lightweight web.

12. The method of claim 10 wherein the lightweight web exhibits deformations when subjected to a tension of about 0.5 pli or less.

13. The method of claim 10 wherein the polymer film coating comprises a polymer selected from the group consisting of low density polyethylene (LDPE), polyolefin plastomers (POP), polyolefin elastomers (POE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), polypropylene (PP), ethylene methyl acrylate copolymer (EMA), ethylene butyl acrylate copolymer (EnBA), ethylene vinyl acetate copolymer (EVA), ethylene acrylic acid copolymer (EAA), ethylene methyl acrylic acid copolymer (EMAA), ionomoers, ethylene vinyl alcohol (EVOH), polyesters such as polyethylene terephthalate (PET), polyamides, and one or more of the foregoing.

14. The method of claim 10 wherein the lightweight web has a MD curl of less than about 3 inches as measured by TAPPI UM 427.

15. The method of claim 10 wherein the lightweight web has insufficient strength properties in the absence of the underlying carrier web to withstand forces imposed upon it in an extruder coating station.

16. The method of claim 10 wherein the carrier web is a heavyweight web.

17. The method of claim 10 wherein the carrier web is a second lightweight web.

18. The method of claim 10 wherein the polymer film coating comprises a coextrusion of at least two layers of polymer films.

19. A method for extrusion coating a lightweight web comprising:

feeding a length of a metal foil, lightweight web along with a length of carrier web to an extruder with the lightweight web atop the carrier web;

extruding a polymer film coating onto the lightweight web and carrier web in the extruder so that a surface of the lightweight web is coated by the extruded coating to provide an extrusion-coated lightweight web; and

separating the extrusion-coated lightweight web from the carrier web.

20. The method of claim 19 wherein the lightweight web has a width less than a width of the carrier web and is affixed to the carrier web by the polymer film coating, and wherein a width of the polymer film coating is greater than the width of the lightweight web.

21. The method of claim 19 wherein the lightweight web exhibits deformations when subjected to a tension of about 0.5 pli or less.

22. The method of claim 19 wherein the polymer film coating comprises a polymer selected from the group consisting of low density polyethylene (LDPE), polyolefin plastomers (POP), polyolefin elastomers (POE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), polypropylene (PP), ethylene methyl acrylate copolymer (EMA), ethylene butyl acrylate copolymer (EnBA), ethylene vinyl acetate copolymer (EVA), ethylene acrylic acid copolymer (EAA), ethylene methyl acrylic acid copolymer (EMAA), ionomoers, ethylene vinyl alcohol (EVOH), polyesters such as polyethylene terephthalate (PET), polyamides, and one or more of the foregoing.

23. The method of claim 19 wherein the lightweight web has a MD curl of less than about 3 inches as measured by TAPPI UM 427.

24. The method of claim 19 wherein the lightweight web has insufficient strength properties in the absence of the underlying carrier web to withstand forces imposed upon it in an extruder coating station.

25. The method of claim 19 wherein the carrier web is a heavyweight web.

26. The method of claim 19 wherein the carrier web is a second lightweight web.

27. The method of claim 19 wherein the polymer film coating comprises a coextrusion of at least two layers of polymer films.

Assignments (28)
RELEASE OF SECURITY INTEREST Recorded Mar 6, 2026
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION (AS SUCCESSOR IN INTEREST TO U.S. BANK NATIONAL ASSOCIATION), AS COLLATERAL AGENT
To: AMPAC HOLDINGS, LLC; AMPAC HOLDCO, INC.; AMPAC FLEXIBLES, LLC; AMPAC FLEXICON, LLC; AMPAC MOBILE HOLDINGS, LLC; AMPAC PACKAGING, LLC; AMPAC PAPER, LLC; AMPAC PLASTICS, LLC; BONITA PACKAGING PRODUCTS, INC.; CEI HOLDINGS, LLC; COATING EXCELLENCE INTERNATIONAL, LLC; GATEWAY PACKAGING COMPANY LLC; JEN-COAT, INC.; MOHAWK NORTHERN PLASTICS, LLC; POLYFIRST PACKAGING, INC.; PROAMPAC HOLDINGS INC.; PROAMPAC ORLANDO INC.; PROAMPAC PG BORROWER LLC; PROAMPAC PG INTERMEDIATE LLC; PROAMPAC REAL ESTATE HOLDINGS LLC; PROAMPAC ROCHESTER LLC; PROLAMINA CORPORATION; PROLAMINA MIDWEST CORPORATION; TRINITY PACKAGING CORPORATION; TULSACK LLC; TWISTED PAPER PRODUCTS, INC.; VITEX PACKAGING, INC.; PAC WORLDWIDE CORPORATION
Reel/Frame 075021/0794 →
ASSIGNMENT OF INTELLECTUAL PROPERTY SECURITY AGREEMENTS Recorded Oct 6, 2023
From: ANTARES CAPITAL LP, AS PREDECESSOR AGENT
To: JPMORGAN CHASE BANK, N.A., AS SUCCESSOR AGENT
Reel/Frame 065165/0919 →
SECURITY INTEREST Recorded Jan 27, 2021
From: AMPAC FLEXIBLES, LLC; AMPAC FLEXICON, LLC; AMPAC HOLDCO, INC.; AMPAC HOLDINGS, LLC; AMPAC MOBILE HOLDINGS, LLC; AMPAC PACKAGING, LLC; AMPAC PAPER, LLC; AMPAC PLASTICS, LLC; BONITA PACKAGING PRODUCTS, INC.; CEI HOLDINGS, LLC; COATING EXCELLENCE INTERNATIONAL, LLC; GATEWAY PACKAGING COMPANY LLC; JEN-COAT, INC.; MOHAWK NORTHERN PLASTICS, LLC; POLYFIRST PACKAGING, INC.; PROAMPAC HOLDINGS INC.; PROAMPAC ORLANDO INC.; PROAMPAC PG BORROWER LLC; PROAMPAC PG INTERMEDIATE LLC; PROAMPAC REAL ESTATE HOLDINGS LLC; PROAMPAC ROCHESTER LLC; PROLAMINA CORPORATION; PROLAMINA MIDWEST CORPORATION; TRINITY PACKAGING CORPORATION; TULSACK LLC; TWISTED PAPER PRODUCTS, INC.; VITEX PACKAGING, INC.
To: U.S. BANK NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 055139/0731 →
RELEASE OF SECURITY INTEREST IN PATENTS RECORDED AT R/F 40997/0067 Recorded Dec 16, 2020
From: ANTARES CAPITAL, LP, AS COLLATERAL AGENT
To: PROLAMINA MIDWEST CORPORATION
Reel/Frame 054789/0791 →
PATENT SECURITY AGREEMENT (SECOND LIEN) Recorded Dec 16, 2016
From: PROLAMINA MIDWEST CORPORATION
To: ANTARES CAPITAL LP, AS COLLATERAL AGENT
Reel/Frame 040997/0067 →
PATENT SECURITY AGREEMENT (FIRST LIEN) Recorded Dec 16, 2016
From: PROLAMINA MIDWEST CORPORATION
To: ANTARES CAPITAL LP, AS COLLATERAL AGENT
Reel/Frame 040997/0025 →
RELEASE OF SECURITY INTEREST Recorded Nov 18, 2016
From: ROYAL BANK OF CANADA
To: AMPAC HOLDINGS, LLC; AMPAC FLEXIBLES, LLC; AMPAC PLASTICS, LLC; PROLAMINA MIDWEST CORPORATION
Reel/Frame 040368/0653 →
RELEASE OF SECURITY INTEREST Recorded Nov 18, 2016
From: ROYAL BANK OF CANADA
To: AMPAC HOLDINGS, LLC; AMPAC FLEXIBLES, LLC; AMPAC PLASTICS, LLC; PROLAMINA MIDWEST CORPORATION
Reel/Frame 040368/0268 →
RELEASE OF SECURITY INTEREST Recorded Oct 28, 2015
From: GENERAL ELECTRIC CAPITAL CORPORATION, AS ADMINISTRATIVE AGENT
To: PROLAMINA MIDWEST CORPORATION
Reel/Frame 036899/0027 →
SECURITY INTEREST Recorded Aug 19, 2015
From: AMPAC HOLDINGS, LLC; AMPAC FLEXIBLES, LLC; AMPAC PLASTICS, LLC; PROLAMINA MIDWEST CORPORATION
To: ROYAL BANK OF CANADA, AS COLLATERAL AGENT
Reel/Frame 036357/0977 →
SECURITY INTEREST Recorded Aug 19, 2015
From: AMPAC HOLDINGS, LLC; AMPAC FLEXIBLES, LLC; AMPAC PLASTICS, LLC; PROLAMINA MIDWEST CORPORATION
To: ROYAL BANK OF CANADA, AS COLLATERAL AGENT
Reel/Frame 036357/0728 →
RELEASE OF SECURITY INTEREST Recorded Sep 13, 2011
From: U.S. BANK NATIONAL ASSOCIATION
To: THILMANY, LLC
Reel/Frame 026897/0583 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 13, 2011
From: THILMANY, LLC
To: PROLAMINA MIDWEST CORPORATION
Reel/Frame 026898/0024 →
SECURITY AGREEMENT Recorded Sep 13, 2011
From: PROLAMINA MIDWEST CORPORATION
To: GENERAL ELECTRIC CAPITAL CORPORATION, AS AGENT
Reel/Frame 026899/0076 →
RELEASE OF SECURITY INTEREST Recorded Sep 13, 2011
From: DEUTSCHE BANK TRUST COMPANY AMERICAS
To: THILMANY, LLC
Reel/Frame 026897/0326 →
SECURITY AGREEMENT Recorded Feb 10, 2011
From: THILMANY, LLC, A DELAWARE LIMITED LIABILITY COMPANY
To: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS REVOLVING COLLATERAL AGENT
Reel/Frame 025780/0439 →
SECURITY AGREEMENT Recorded Feb 7, 2011
From: THILMANY, LLC, A DELAWARE LIMITED LIABILITY COMPANY
To: U.S. BANK NATIONAL ASSOCIATION, AS NOTES COLLATERAL AGENT
Reel/Frame 025751/0488 →
RELEASE - 07/17/2006, 017946/0790 Recorded Feb 4, 2011
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS REVOLVING COLLATERAL AGENT
To: THILMANY, LLC, A DELAWARE LLC
Reel/Frame 025743/0758 →
RELEASE - 07/17/2006, 017946/0758 Recorded Feb 3, 2011
From: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS TERM COLLATERAL AGENT
To: THILMANY, LLC, A DELAWARE LLC
Reel/Frame 025738/0740 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 1, 2006
From: PACKAGING DYNAMICS CORPORATION
To: THILMANY LLC
Reel/Frame 018471/0371 →
GRANT OF SECURITY INTEREST 2ND LIEN Recorded Jul 17, 2006
From: PACKAGING DYNAMICS CORPORATION
To: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS REVOLVING COLLATERAL AGENT
Reel/Frame 017946/0790 →
GRANT OF SECURITY INTEREST - FIRST LIEN Recorded Jul 17, 2006
From: PACKAGING DYNAMICS CORPORATION
To: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS TERM COLLATERAL AGENT
Reel/Frame 017946/0758 →
RELEASE OF SECURITY INTEREST Recorded Jul 11, 2006
From: JEFFERIES BABSON FINANCE LLC
To: THILMANY, LLC
Reel/Frame 017911/0966 →
CHANGE OF NAME Recorded Jun 23, 2006
From: THILMANY, INC.
To: PACKAGING DYNAMICS CORPORATION
Reel/Frame 018026/0344 →
CONVERSION Recorded Jun 23, 2006
From: THILMANY, LLC
To: THILMANY, INC.
Reel/Frame 018026/0337 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 17, 2005
From: INTERNATIONAL PAPER COMPANY
To: THILMANY, LLC
Reel/Frame 016164/0284 →
SECURITY AGREEMENT Recorded Jun 10, 2005
From: THILMANY, LLC
To: JEFFERIES BABSON FINANCE LLC, AS ADMINISTRATIVE AGENT
Reel/Frame 016116/0359 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 16, 2001
From: KNAUF, GARY H.
To: INTERNATIONAL PAPER COMPANY, (A NEW YORK CORPORATION)
Reel/Frame 012265/0600 →