Ultra thin laminate with particulates in dense packages

Abstract

The present invention is directed to a method of forming a laminate absorbent structure, and a resulting package containing a single continuous running web of the laminate material. Notably, formation of the material is effected by blending a curtain of adhesive fibers with a curtain of particulate material, and depositing the mixture on a moving substrate, preferably provided in the form of a tissue layer. A second substrate, also preferably comprising a tissue layer, is applied on top of the deposited mixture, and pressure applied to form the laminated structure. Notably, attendant to packaging of the laminated material, adjacent layers of the material tend to nest into one another, to form a sandwich in which the density of the material in the package is more than 1.5 times the density of the material after its removal from the package.

1 . A package containing a single continuous running web of laminated material with the package comprising adjacent layers, where the laminated material comprises a layer of tissue laminated to a layer of particulate mixed with adhesive fibers laminated to a second layer of tissue, to form a sandwich, in which the Material Density in the package is more than 1.5 times the Density of the material after removing it from the package. 
     
     
         2 . The package according to  claim 1  where the package is a roll, a festooned package, or a spool. 
     
     
         3 . A roll containing a continuous running web of laminated material comprising a layer of tissue laminated to a layer of particulate mixed with adhesive fibers laminated to a second layer of tissue to form a sandwich, in which the Material Density in the package is more than 3 times the Density of the material when it is removed from the package. 
     
     
         4 . The material according to  claim 3  in which the Wind Layer Thickness is less than 0.3 mm. 
     
     
         5 . The material according to  claim 3  in which the Wind Layer Thickness is less than 0.27 mm. 
     
     
         6 . The roil, according to  claim 3 , which contains more than 3000 lineal meters of material. 
     
     
         7 . The festooned package according to  claim 2  that contains more than 2000 square meters. 
     
     
         8 . A method of making a laminate absorbent material, comprising the steps of:
 providing a first moving substrate comprising a cellulosic fibrous web;   providing a supply of adhesive material in the form of a curtain of adhesive fibers;   providing a supply of particulate absorbent material in the form of a curtain of particulate material;   blending said curtain of particulate material with said curtain of adhesive fibers above said first moving substrate at a distance of no more than about 2.5 centimeters above the moving substrate to form a mixture of said particulate material and said adhesive fibers, and depositing said mixture on the moving substrate, and   providing a second substrate comprising another cellulosic fibrous web, and placing the second substrate on top of said mixture deposited on said first substrate to form a laminate; and   applying pressure to said laminate, whereby said adhesive fibers bond said particulate material to said first and second substrates while bonding said substrates to each other to form said laminate absorbent material.   
     
     
         9 . A method of forming a laminate absorbent material in accordance with  claim 8 , including
 packaging said laminate absorbent structure by one of rolling and festooning or spooling, whereby the packaged laminate absorbent structure exhibits a Material Density in the package greater than the Density of the laminate absorbent material removed from the package.   
     
     
         10 . A method of forming a laminate absorbent material in accordance with  claim 9 , wherein
 the Density Ratio of said Material Density in the package to the Density of the laminate absorbent material removed from the package is between about 1.5 and 5.0.   
     
     
         11 . A method of forming a laminate absorbent material in accordance with  claim 9 , wherein after storage in the package, the VDS value is increased by at least 3 Newtons compared to the VDS of the material immediately prior to packaging. 
     
     
         12 . A method of forming a laminate absorbent material in accordance with  claim 8 , including
 secondarily bonding said laminate by compaction, subsequent to said pressure-applying step, to enhance resistance of said laminate to delamination, including limiting the pressure applied during said pressure-applying step to avoid crushing of said particulate absorbent material.