IP Library › Granted Patent US 7,144,831
Granted Patent B2
US 7,144,831 · App. 10/205,690 · Granted Dec 5, 2006

Three-dimensional nonwoven substrate having sub-millimeter orifice structure

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Quick Facts
Patent No.
US 7,144,831
App. No.
10/205,690
Granted
Dec 5, 2006
Kind
B2
Abstract

The present invention is directed to a nonwoven fabric having a combination of a planar background element and projection elements to form a three-dimensional pattern, and a plurality of durable sub-millimeter orifices that extend at least partially through the depth of the three-dimensional pattern. The three-dimensional image of the non-apertured nonwoven fabric enhances the treatment, cleaning or cleansing performance due to pronounced surface projections that come in contact with the object to be treated or cleaned, and provide air passageways that are parallel to the plane of the substrate. Incorporation of sub-millimeter orifices in the nonwoven fabric, which extend through at least part of the nonwoven fabric, allow for transmission of fluids, as well as applied or embedded chemistries, from one side or surface of the substrate, or from a region internal to the nonwoven fabric, to the side which is in communication with the formed orifice.

Claims (19)

1. An imaged nonwoven fabric comprising;

a) a planar background element, wherein said planar background element exhibits an obverse and a reverse side or surface connected by an intermediate region;

b) at least one projection element extending out from said planar background element, wherein said projection element exhibits an obverse and a reverse side or surface connected by an intermediate region, said at least one projection element having been formed by hydraulic displacement of fibers;

c) a plurality of orifices which extend partially through said fabric, from said intermediate region through at least one side or surface of at least one said planar background element or projection element, said plurality of orifices having been formed by hydraulic displacement of fibers; and

d) wherein said orifices have a diameter of about 0.03 to 0.5 millimeter.

2. A nonwoven fabric as in claim 1 , including a further plurality of orifices having a first geometric profile or regional positioning extending completely through the planar background element, and/or the projection element.

3. A nonwoven fabric as in claim 1 , wherein the imaged nonwoven fabric is a substrate for a medical treatment product.

4. A nonwoven fabric as in claim 1 , wherein the imaged nonwoven fabric is a substrate for an industrial cleaning product.

5. A nonwoven fabric as in claim 1 , wherein the imaged nonwoven fabric is a substrate for a hygienic cleansing product.

6. A nonwoven fabric comprising;

a) a planar background element, wherein said planar background element exhibits an obverse and a reverse side or surface connected by an intermediate region;

b) at least one projection element extending out from said planar background element, wherein said projection element exhibits an obverse and a reverse side or surface connected by an intermediate region, said at least one projection element having been formed by hydraulic displacement of fibers;

c) a plurality of orifices which extend through at least one side or surface of at least one said planar background element or projection element, said plurality of orifices having been formed by hydraulic displacement of fibers; and

d) wherein said orifices have a diameter of about 0.03 to 0.5 millimeter, wherein a first population of said orifices extend from the intermediate region of said projection element through the obverse or reverse side of said projection element and a second population of orifices extend from the intermediate region of said planar background element through the obverse or reverse side of said planar background element.

7. A nonwoven fabric comprising;

a) a planar background element, wherein said planar background element exhibits an obverse and a reverse side or surface connected by an intermediate region;

b) at least one projection element extending out from said planar background element, wherein said projection element exhibits an obverse and a reverse side or surface connected by an intermediate region, said at least one projection element having been formed by hydraulic displacement of fibers;

c) a plurality of orifices which extend through at least one side or surface of at least one said planar background element or projection element, said plurality of orifices having been formed by hydraulic displacement of fibers; and

d) wherein said orifices have a diameter of about 0.03 to 0.5 millimeter, wherein a first population of said orifices having a first geometric profile or regional positioning extend from the intermediate region through the obverse or reverse side of said planar background element, and a second population of said orifices having a second geometric profile or regional positioning extend from the intermediate region through the obverse or reverse side of said projection element.

Assignments (28)
RELEASE OF SECURITY INTEREST Recorded May 4, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: PLIANT, LLC; FIBERWEB, LLC; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; AVINTIV SPECIALTY MATERIALS INC.; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
Reel/Frame 071165/0753 →
RELEASE OF SECURITY INTEREST Recorded May 3, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
Reel/Frame 071165/0259 →
RELEASE OF SECURITY INTEREST Recorded May 3, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL & SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.
Reel/Frame 071165/0323 →
RELEASE OF SECURITY INTEREST Recorded May 3, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; AVINTIV SPECIALTY MATERIALS INC.; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
Reel/Frame 071165/0365 →
PARTIAL RELEASE OF SECURITY INTEREST IN PATENTS Recorded May 2, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
Reel/Frame 071161/0598 →
PARTIAL RELEASE OF SECURITY INTEREST IN PATENTS Recorded May 2, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL & SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.
Reel/Frame 071156/0179 →
PARTIAL RELEASE OF SECURITY INTEREST IN PATENTS Recorded May 2, 2025
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
Reel/Frame 071161/0202 →
RELEASE OF SECURITY INTEREST Recorded Nov 5, 2024
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: BERRY FILM PRODUCTS COMPANY, INC.; AVINTIV SPECIALTY MATERIALS, LLC (F/K/A AVINTIV SPECIALTY MATERIALS INC.; F/K/A POLYMER GROUP, INC.); FIBERWEB, LLC.; PROVIDENCIA USA, INC.
Reel/Frame 069306/0067 →
CORRECTIVE ASSIGNMENT TO CORRECT THE APPLICATION NUMBERS PREVIOUSLY RECORDED AT REEL: 055009 FRAME: 0450. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY AGREEMENT. Recorded Jun 21, 2023
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 064050/0207 →
CORRECTIVE ASSIGNMENT TO CORRECT THE APPLICATION NUMBERS PREVIOUSLY RECORDED AT REEL: 056759 FRAME: 0001. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY INTEREST. Recorded Jun 21, 2023
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; AVINTIV SPECIALTY MATERIALS INC.; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 064050/0377 →
CORRECTIVE ASSIGNMENT TO CORRECT THE APPLICATION NUMBERS PREVIOUSLY RECORDED AT REEL: 055616 FRAME: 0527. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY AGREEMENT. Recorded Jun 21, 2023
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 064050/0620 →
CORRECTIVE ASSIGNMENT TO CORRECT THE LISTING OF PATENTS PREVIOUSLY RECORDED AT REEL: 055742 FRAME: 0522. ASSIGNOR(S) HEREBY CONFIRMS THE FIRST LIEN PATENT SECURITY AGREEMENT. Recorded Jun 21, 2023
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 064053/0415 →
CORRECTIVE ASSIGNMENT TO CORRECT THE LISTING OF PATENTS PREVIOUSLY RECORDED AT REEL: 058954 FRAME: 0677. ASSIGNOR(S) HEREBY CONFIRMS THE FIRST LIEN PATENT SECURITY AGREEMENT. Recorded Jun 21, 2023
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 064053/0867 →
CORRECTIVE ASSIGNMENT TO CORRECT THE LISTING OF PATENTS PREVIOUSLY RECORDED ON REEL 054840 FRAME 0047. ASSIGNOR(S) HEREBY CONFIRMS THE FIRST LIEN PATENT SECURITY AGREEMENT. Recorded Jun 21, 2023
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 064142/0855 →
CORRECTIVE ASSIGNMENT TO CORRECT THE THE LISTING OF PATENTS PREVIOUSLY RECORDED AT REEL: 054840 FRAME: 0047. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Jan 31, 2022
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 058954/0581 →
CORRECTIVE ASSIGNMENT TO CORRECT THE THE LISTING OF PATENTS PREVIOUSLY RECORDED AT REEL: 055009 FRAME: 0450. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded Jan 31, 2022
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 058954/0677 →
SECURITY INTEREST Recorded Jul 3, 2021
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; AVINTIV SPECIALTY MATERIALS INC.; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 056759/0001 →
CORRECTIVE ASSIGNMENT TO CORRECT THE LISTING OF PATENTS PREVIOUSLY RECORDED AT REEL: 054840 FRAME: 0047. ASSIGNOR(S) HEREBY CONFIRMS THE FIRST LIEN PATENT SECURITY AGREEMENT. Recorded Mar 11, 2021
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 055616/0527 →
CORRECTIVE ASSIGNMENT TO CORRECT THE LISTING OF PATENTS PREVIOUSLY RECORDED ON REEL 055009 FRAME 0450. ASSIGNOR(S) HEREBY CONFIRMS THE FIRST LIEN PATENT SECURITY AGREEMENT. Recorded Mar 11, 2021
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 055742/0522 →
FIRST LIEN PATENT SECURITY AGREEMENT Recorded Jan 15, 2021
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 055009/0450 →
FIRST LIEN PATENT SECURITY AGREEMENT Recorded Dec 23, 2020
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL AND SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.; LETICA CORPORATION
To: U.S. BANK NATIONAL ASSOCIATION
Reel/Frame 054840/0047 →
FIRST LIEN PATENT SECURITY AGREEMENT Recorded Jan 6, 2020
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL & SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.
To: U.S. BANK NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 051485/0318 →
FIRST LIEN PATENT SECURITY AGREEMENT Recorded Jul 2, 2019
From: BERRY GLOBAL, INC.; BERRY FILM PRODUCTS COMPANY, INC.; BPREX HEALTHCARE PACKAGING INC.; PRIME LABEL & SCREEN, INC.; AVINTIV SPECIALTY MATERIALS INC.; PRIME LABEL & SCREEN INCORPORATED; PLIANT, LLC; FIBERWEB, LLC; BERRY GLOBAL FILMS, LLC; PROVIDENCIA USA, INC.
To: U.S. BANK NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 049671/0171 →
SECOND LIEN SECURITY AGREEMENT Recorded Oct 7, 2015
From: AVINTIV INC. (INDIVIDUALLY AND AS SUCCESSOR BY MERGER TO BERRY PLASTICS ACQUISITION CORPORATION IX); PGI POLYMER, INC.; CHICOPEE, INC.
To: U.S. BANK NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 036799/0627 →
FIRST LIEN SECURITY AGREEMENT Recorded Oct 6, 2015
From: AVINTIV INC. (INDIVIDUALLY AND AS SUCCESSOR BY MERGER TO BERRY PLASTICS ACQUISITION CORPORATION IX); AVINTIV SPECIALTY MATERIALS, INC.; PGI POLYMER, INC.; CHICOPEE, INC.
To: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH, AS TERM COLLATERAL AGENT; BANK OF AMERICA, N.A., AS ABL COLLATERAL AGENT
Reel/Frame 036788/0041 →
RELEASE OF SECURITY INTEREST Recorded Oct 2, 2015
From: WILMINGTON TRUST COMPANY
To: AVINTIV SPECIALTY MATERIALS, INC. (F/K/A POLYMER GROUP, INC.)
Reel/Frame 036743/0667 →
RELEASE OF SECURITY INTEREST Recorded Oct 2, 2015
From: CITIBANK, N.A.
To: AVINTIV SPECIALTY MATERIALS, INC. (F/K/A POLYMER GROUP, INC.)
Reel/Frame 036743/0900 →
CHANGE OF NAME Recorded Jul 20, 2015
From: POLYMER GROUP, INC.
To: AVINTIV SPECIALTY MATERIALS INC.
Reel/Frame 036132/0354 →