IP Library › Granted Patent US 10,071,870
Granted Patent B2
US 10,071,870 · App. 15/071,553 · Granted Sep 11, 2018

Methods of winding substrates having three-dimensional features

Inventors: Gueltekin Erdem (Bad Soden, DE); Nadezhda Kurbatova (Schwalbach Am Taunus, DE); Joseph Hung Lam (Mason, OH); Sudhanshu Gupta (Euskirchen, DE)
Assignee: The Procter & Gamble Company
B65H18/10A61F13/15747A61F13/15764B65H18/28B65H2301/412845B65H2701/18444B65H2801/57
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Quick Facts
Patent No.
US 10,071,870
App. No.
15/071,553
Granted
Sep 11, 2018
Kind
B2
Abstract

The present disclosure provides methods of winding substrates comprising three-dimensional features about a core to form a spool so that at least a majority of the three-dimensional features in one wrap of a lane of the spool are at least partially nested with a majority of the three-dimensional features in another adjacent wrap in the same lane of the spool. By at least partially nesting these three-dimensional features in adjacent wraps of a lane of the spool, the three-dimensional features may be at least mostly maintained in the substrates without significant compression during winding and storage of the spool.

Claims (50)

1. A method of winding a substrate comprising a nonwoven on a core to create a spool of the substrate, wherein the substrate comprises a plurality of three-dimensional features, and wherein the core defines a longitudinal axis and has a first end and second end, the method comprising:

spirally winding a plurality of wraps of the substrate about the core to at least partially form a first lane, wherein a majority of the three-dimensional features in at least some of the wraps of the first lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap in the first lane;

helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to a second lane;

spirally winding a plurality of wraps of the substrate about the core to at least partially form the second lane, wherein a majority of the three-dimensional features in at least some of the wraps of the second lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the second lane;

helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to a third lane;

spirally winding a plurality of wraps of the substrate about the core to at least partially form the third lane, wherein a majority of the three-dimensional features in at least some of the wraps of the third lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the third lane; and

applying less than 10% machine direction strain on the substrate during the spirally and helically winding steps.

2. The method of claim 1 , comprising:

helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to a fourth lane; and

spirally winding a plurality of wraps of the substrate about the core to at least partially form the fourth lane, wherein a majority of the three-dimensional features in at least some of the wraps of the fourth lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the fourth lane.

3. The method of claim 2 , comprising:

helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to a fifth lane; and

spirally winding a plurality of wraps of the substrate about the core to at least partially form the fifth lane, wherein a majority of the three-dimensional features in at least some of the wraps of the fifth lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the fifth lane.

4. The method of claim 1 , comprising fully spirally winding the first lane prior to spirally winding the second lane.

5. The method of claim 4 , comprising fully spirally winding the second lane prior to spirally winding the third lane.

6. The method claim 5 , comprising:

fully winding the spool in a first direction extending from the first end to the second end; or

fully winding the spool in a second direction extending from the second end to the first end.

7. The method of claim 1 , wherein the first lane is positioned adjacent to the second lane, and wherein the second lane is positioned adjacent to the third lane.

8. The method of claim 1 , comprising only partially spirally winding the first lane prior to transitioning to the second lane.

9. The method of claim 8 , comprising only partially spirally winding the second lane prior to transitioning to the third lane.

10. The method of claim 9 , wherein the first lane, the second lane, and the third lane extend in a first direction extending between the first end and the second end.

11. The method of claim 1 , comprising helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core to transition to an end lane positioned proximate to the second end.

12. The method of claim 11 , comprising spirally winding a plurality of wraps of the substrate about the core to form the end lane, wherein a majority of the three-dimensional features in at least some of the wraps of the end lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the end lane.

13. The method of claim 12 , comprising spirally winding a greater number of wraps in the end lane than in the third lane.

14. The method of claim 13 , comprising helically winding at least a ⅕ wrap to at most 2 wraps of the substrate about the core in a direction extending from the second end toward the first end.

15. The method of claim 14 , comprising spirally winding a second plurality of wraps of the substrate about the core to continue to spirally wind the third lane, wherein a majority of the three-dimensional features in at least some of the second plurality of the wraps of the third lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the second plurality of wraps of the third lane.

16. The method of claim 15 , comprising:

helically winding at least a ⅕ wrap to at most 2 wraps about the core in a direction extending from the second end to the first end to transition to the second lane; and

spirally winding a second plurality of wraps of the substrate about the core to continue to form the second lane, wherein a majority of the three-dimensional features in at least some of the second plurality of the wraps of the second lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the second plurality of wraps of the second lane.

17. The method of claim 16 , comprising:

helically winding at least a ⅕ wrap to at most 2 wraps about the core in a direction extending from the second end to the first end to transition to the first lane; and

spirally winding a second plurality of wraps of the substrate about the core to continue to spirally wind the first lane, wherein a majority of the three-dimensional features in at least some of the second plurality of the wraps of the first lane are at least partially nested with a majority of the three-dimensional features in an adjacent wrap of the second plurality of wraps of the first lane.

18. The method of claim 1 , wherein the plurality of three-dimensional features comprise a plurality of projections on a first side of the substrate that form a plurality of recesses on a second side of the substrate.

19. The method of claim 18 , wherein the plurality of three-dimensional features comprise a plurality of second recesses on a first side of the substrate and a plurality of second projections on the second side of the substrate.

20. The method of claim 1 , wherein the substrate comprises apertures.

21. The method of claim 1 , comprising applying less than 5% MD strain on the substrate during the spirally and helically winding steps.

22. A method of winding a three-dimensional substrate on a core to create a spool of the three-dimensional substrate, wherein the three-dimensional substrate comprises a plurality of projections on a first side of the substrate that form a plurality of recesses on a second side of the substrate, and wherein the core defines a longitudinal axis and has a first end and second end, the method comprising:

spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form a first lane, wherein a majority of the projections in at least some of the wraps of the first lane are at least partially nested with a majority of the recesses in an adjacent wrap in the first lane;

helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a second lane, wherein the first lane is positioned more proximal to the first end than the second lane;

spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the second lane, wherein a majority of the projections in at least some of the wraps of the second lane are at least partially nested with a majority of the recesses in an adjacent wrap of the second lane;

helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a third lane, wherein the third lane is positioned more proximal to the second end than the second lane;

spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the third lane, wherein a majority of the projections in at least some of the wraps of the third lane are at least partially nested with a majority of the recesses in an adjacent wrap of the third lane; and applying less than 10% machine direction strain on the substrate during the spirally and helically winding steps.

23. A method of winding a three-dimensional substrate on a core to create a spool of the three-dimensional substrate, wherein the three-dimensional substrate comprises a plurality of projections on a first side of the substrate that form a plurality of recesses on a second side of the substrate, and wherein the core defines a longitudinal axis and has a first end and second end, the method comprising:

spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form a first lane, wherein a majority of the projections in at least some of the wraps of the first lane are at least partially nested with a majority of the recesses in an adjacent wrap in the first lane;

helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a second lane, wherein the first lane is positioned more proximal to the first end than the second lane;

spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the second lane, wherein a majority of the projections in at least some of the wraps of the second lane are at least partially nested with a majority of the recesses in an adjacent wrap of the second lane;

helically winding at least a ⅕ wrap to at most 2 wraps of the three-dimensional substrate about the core to transition to a third lane, wherein the third lane is positioned more proximal to the second end than the second lane;

spirally winding a plurality of wraps of the three-dimensional substrate about the core to at least partially form the third lane, wherein a majority of the projections in at least some of the wraps of the third lane are at least partially nested with a majority of the recesses in an adjacent wrap of the third lane;

wherein the helically winding comprises less than 35% of the spool; and applying less than 10% machine direction strain on the substrate during the spirally and helically winding steps.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 21, 2016
From: ERDEM, GUELTEKIN; KURBATOVA, NADEZHDA; LAM, JOSEPH HUNG; GUPTA, SUDHANSHU
To: THE PROCTER & GAMBLE COMPANY
Reel/Frame 038338/0064 →
Continuity (2)
Provisional Application 62138426 · Mar 26, 2015
Related Publication 20160280503A1 · Sep 29, 2016