IP Library › Granted Patent US 12,258,684
Granted Patent B2
US 12,258,684 · App. 17/729,323 · Granted Mar 25, 2025

Process for making fibrous structures

Inventors: Steven Lee Barnholtz (West Chester, OH); Paul Dennis Trokhan (Hamilton, OH); Michael Donald Suer (Cincinnati, OH); Douglas Jay Barkey (Maineville, OH); Jonathan Paul Brennan (Cincinnati, OH); Ronald Thomas Gorley (Cincinnati, OH)
Assignee: The Procter & Gamble Company
D01D5/0985B32B5/022B32B37/203D01F6/625D04H1/425D04H1/4291D04H1/56D04H1/565D04H3/16D04H5/06D10B2201/22D10B2321/02D10B2321/022D10B2321/06D10B2331/02D10B2331/04D10B2331/041D10B2401/12D10B2509/026
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Quick Facts
Patent No.
US 12,258,684
App. No.
17/729,323
Granted
Mar 25, 2025
Kind
B2
Abstract

Processes for making fibrous structures and more particularly processes for making fibrous structures comprising filaments are provided.

Claims (19)

1. A process for making a fibrous structure, the process comprising the steps of:

a. providing a die comprising three or more rows of three or more filament-forming holes and fluid-releasing holes associated with the filament-forming holes;

b. supplying at least a first polymer to the die;

c. supplying a fluid to the die such that the fluid exits the fluid-releasing holes;

d. producing a plurality of filaments comprising the first polymer from the die wherein the die comprises filament-forming holes such that the plurality of filaments comprise single filaments each produced from a single filament-forming hole, wherein the fluid exiting the fluid-releasing holes attenuates one or more of the single filaments by converging and contacting an external surface of the single filaments such that the plurality of filaments exhibit an average filament diameter distribution greater than the average filament diameter distribution of filaments produced from the first polymer from a knife-edge die;

e. combining the plurality of filaments with solid additives to form a mixture; and

f. collecting the mixture on a collection device to produce a fibrous structure.

2. The process according to claim 1 wherein more than one fluid-releasing hole is associated with a filament-forming hole.

3. The process according to claim 1 wherein one fluid-releasing hole is concentrically positioned around one filament-forming hole.

4. The process according to claim 1 wherein the first polymer comprises a synthetic polymer.

5. The process according to claim 4 wherein the synthetic polymer is selected from the group consisting of: polyvinyl alcohol, polyvinyl alcohol derivatives, polyesters, nylons, polyolefins, polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.

6. The process according to claim 4 wherein the synthetic polymer comprises a polyolefin.

7. The process according to claim 6 wherein the polyolefin comprises polypropylene.

8. The process according to claim 1 wherein the first polymer comprises a natural polymer.

9. The process according to claim 8 wherein the natural polymer is selected from the group consisting of: starch, starch derivatives, cellulose, cellulose derivatives, hemicellulose, hemicellulose derivatives and mixtures thereof.

10. The process according to claim 1 wherein the first polymer comprises a compostable polymer.

11. The process according to claim 10 wherein the compostable polymer is selected from the group consisting of: polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.

12. The process according to claim 1 wherein the solid additives comprise fibers.

13. The process according to claim 12 wherein the fibers comprise wood pulp fibers.

Continuity (6)
Continuation 16702920 · Dec 4, 2019
Continuation 15891726 · Feb 8, 2018
Continuation 14475699 · Sep 3, 2014
Continuation 12170575 · Jul 10, 2008
Provisional Application 60959885 · Jul 17, 2007
Related Publication 20220325440A1 · Oct 13, 2022
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Declaration of Gajanan S, Bhat, Ph.D, U.S. Pat. No. 11,326,276, FITESA/Exhibit 1015, No Known Date, 149 pages. [cited by applicant]
G. S. Bhat et al., Polymer-laid web Formation, Handbook ofNonwovens, edited by S.J. Russel, Woodhead PublishingLimited, dated Dec. 2007, pp. 143-200. [cited by applicant]
John G. McCulloch, The History of the Development of MeltBlowing Technology, International Nonwovens Journal, FITESA/Exhibit 1010, dated Mar. 1999, 11 pgs. [cited by applicant]
Randall R. Bresee et al., Influence of Processing Conditions on Melt Blown Web Structure: Part 1—DCD, Department of Materials Science & Engineering, the University of Tennessee, FITESA/Exhibit 1025, INJ Spring year 2004… [cited by applicant]
Randall R. Bresee et al., Influence of Processing Conditions on Melt Blown Web Structure: Part 2—Primary Airflow Rate, Department of Materials Science & Engineering, the University of Tennessee, FITESA/Exhibit 1026, INJ… [cited by applicant]
Ron (Rongguo) Zhao, Melt Blown Dies: A Hot Innovation Spot, Textiles and Nonwovens Development Center, University of Tennessee, INJ Winter 2002, FITESA/Exhibit 1011, year 2002, 5 pgs. [cited by applicant]
Youngchul Lee et al., Effects of melt-blowing process conditions on morphological and mechanical properties of polypropylene webs, Textile Materials Research Laboratory, Center for Materials Processing, University of Te… [cited by applicant]