Polymer transfer apparatus, methods, and composite webs

1. A method for producing a composite web, the method comprising:

providing a forming tool comprising an exterior surface that comprises one or more depressions formed therein;

delivering a molten thermoplastic composition onto the exterior surface of the forming tool;

maintaining the exterior surface of the forming tool at a roll temperature that is below a melt processing temperature of the thermoplastic composition;

wiping the molten thermoplastic composition on the exterior surface of the forming tool, wherein at least some of the molten thermoplastic composition enters the one or more depressions; transferring the thermoplastic composition in the one or more depressions to a substrate by contacting a first major surface of the substrate to the thermoplastic composition in the one or more depressions, wherein a portion of the thermoplastic composition in the one or more depressions that is proximate surfaces of the one or more depressions falls below the melt processing temperature of the thermoplastic composition after the depositing and before the thermoplastic composition in the one or more depressions contacts the first major surface of the substrate; and

separating the substrate and the thermoplastic composition in the one or more depressions from the forming tool after the transferring, wherein a composite web is formed that comprises one or more polymeric structures of the thermoplastic composition located on the first major surface of the substrate.

2. A method according to claim 1 , wherein a portion of the thermoplastic composition in the one or more depressions that is distal from surfaces of the one or more depressions remains at or above the melt processing temperature at least until the thermoplastic composition in the one or more depressions contacts the first major surface of the substrate.

3. A method according to claim 1 , wherein the roll temperature is 20 degrees Celsius or more below a molten thermoplastic composition temperature at which the molten thermoplastic composition is delivered to the exterior surface of the forming tool.

4. A method according to claim 1 , wherein delivering the molten thermoplastic composition onto the exterior surface of the forming tool comprises extruding the molten thermoplastic composition into an interface between the exterior surface of the forming tool and a doctor blade.

5. A method according to claim 1 , wherein delivering the molten thermoplastic composition onto the exterior surface of the tuning tool comprises extruding the molten thermoplastic composition onto a doctor blade, wherein the molten thermoplastic composition flows down a surface of the doctor blade to an interface between the doctor blade and the exterior surface of the roll.

6. A method according to claim 1 , wherein the first major surface of the substrate comprises a porous surface, and wherein the transferring further comprises forcing a portion of the first major surface of the substrate against the thermoplastic composition in the one or more depressions, wherein a portion of the thermoplastic composition in at least some depressions of the one or more depressions infiltrates the porous surface.

7. A method according to claim 3 , wherein the porous surface of the substrate comprises fibers, and further wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the thermoplastic composition in the one or more depressions.

8. A method according to claim 1 , wherein the first major surface of the substrate comprises fibers, and further wherein the transferring further comprises encapsulating at least a portion of at least some of the fibers in the thermoplastic composition in the one or more depressions by forcing the first major surface of the substrate against the thermoplastic composition in the one or more depressions.

9. A method according to claim 1 , wherein the substrate comprises polymeric material with a melt processing temperature at or below the melt processing temperature of the thermoplastic composition in the one or more depressions.

10. A method according to claim 1 , wherein the thermoplastic composition comprises one or more elastomeric polymeric components such that the one or more polymeric structures on the substrate exhibit elastic behavior.

11. A method according to claim 1 , wherein the thermoplastic composition comprises one or more elastomeric polymeric components such that the one or more polymeric structures on the substrate exhibit elastic behavior, and wherein the method further comprises stretching the composite web with the one or more polymeric structures located thereon such that the substrate exhibits permanent elongation after the stretching.

12. A method according to claim 1 , wherein the thermoplastic composition comprises one or more elastomeric polymeric components such that the one or more polymeric structures on the substrate exhibit elastic behavior, and wherein the substrate comprises an elastic substrate, and further wherein the method comprises stretching the elastic substrate before contacting the first major surface of the web with the thermoplastic composition in the one or more depressions.

13. A method according to claim 1 , wherein the wiping leaves at least some of the molten thermoplastic composition on the exterior surface of the forming tool outside of the one or more depressions.

14. A method according to claim 1 , wherein depositing the molten thermoplastic composition on the exterior surface of the forming tool comprises depositing two or more different molten thermoplastic compositions on the exterior surface of the forming tool.

15. A method according to claim 1 , wherein at least some of the one or more depressions comprise cavities formed therein, wherein the one or more polymeric structures formed by the one or more depressions comprise surface features located on an upper surface thereof.

16. A method according to claim 15 , wherein the surface features are formed at the same time as the one or more polymeric structures.