Ultrasonically bonded multilayer form and methods of making same

Abstract

The invention provides a water blocking tape for use in a variety of cable designs, such as power cable, data communications cable and telecommunications cable. A water blocking tape according to the invention includes layers of lightweight nonwoven fabric with one or more swellable water blocking compounds, such as water absorbent polymers, disposed between the layers. The nonwoven fabric layers are bonded in a pattern using an ultrasonic bonding technique. The bonding pattern helps to contain and to restrain movement of the water blocking compounds between the layers. The bonding pattern compartmentalizes the water blocking compounds to prevent pooling of the compounds and to facilitate a substantially consistent distribution of the compounds between the layers such that when a tape contacts water, the tape achieves a substantially consistent swell height. A substantially consistent swell height permits a tape to serve as a reliable water barrier to prevent damage and degradation of a cable and its components. Ultrasonic bonding of the multilayer tape eliminates the need and use of adhesives and bonding agents to form the tape that can have inhibiting effects on a swelling action of the tape. The invention further provides a multilayer form or substrate produced using an ultrasonic bonding technique and having disposed between adjacent layers one or more non-fluid compounds that have one or more physical properties or characteristics, such as, for instance, odor-absorbing properties, heat absorbing properties, humidity or moisture absorption properties, fragrant properties, thermal properties, as well as any of other required or desired physical properties or characteristics.

What is claimed is: 
     
         1 . An apparatus for assembling a multilayer form, wherein the multilayer form comprises:
 at least a first layer of material;   at least one non-fluid compound disposed on a surface of the first layer of material wherein the at least one non-fluid compound comprises one or more water blocking compounds;   at least a second layer of material disposed on the non-fluid compound such that the non-fluid compound is disposed between the first layer and the second layer of material; and   the first and the second layer of material being ultrasonically bonded along a pattern, the pattern traversing at least a portion of an outer surface of the first layer and at least a portion of an outer surface of the second layer of material when bonded such that movement of the non-fluid compound between the first layer and the second layer of material is restrained;   and the first and second layer of material being further ultrasonically bonded and cut along the edges by the apparatus, the apparatus comprising one or more cutting devices and an ultrasound source to form one or more multilayer forms;   wherein the one or more cutting devices of the apparatus comprises one or more cutting anvils;   wherein the ultrasound source of the apparatus comprises one or more ultrasonic horns;   wherein the one or more cutting anvils of the apparatus are disposed on opposite sides of the multilayer form from the one or more ultrasonic horns; and,   wherein the at least one non-fluid compound is selected from the group consisting of moist compounds, moist pastes, semi-solid compounds, gels, waxes and combinations thereof.   
     
     
         2 . The apparatus of  claim 1  wherein the pattern includes a plurality of lines. 
     
     
         3 . The apparatus of  claim 2  wherein the plurality of lines defines one or more shapes. 
     
     
         4 . The apparatus of  claim 3  wherein each of the one or more shapes defines a volume to contain an amount of the at least one non-fluid compound. 
     
     
         5 . The apparatus of  claim 2  wherein the pattern includes a repeating and substantially uniform pattern such that the plurality of lines defines a plurality of substantially similar shapes. 
     
     
         6 . The apparatus of  claim 5  wherein each of the plurality of substantially similar shapes defines a volume to contain an amount of the at least one non-fluid compound. 
     
     
         7 . The apparatus of  claim 6  wherein each shape defines a substantially similar volume to contain a substantially similar amount of the at least one non-fluid compound. 
     
     
         8 . The apparatus of  claim 1  wherein the first layer of material defines substantially similar dimensions as the second layer of material defines. 
     
     
         9 . The apparatus of  claim 1  wherein one of the first layer of material and the second layer of material includes a layer of nonwoven material. 
     
     
         10 . The apparatus of  claim 9  wherein the layer of nonwoven material includes a layer of material selected from the group consisting of a spun bonded nonwoven fabric, a spun bonded melt blown spun bonded nonwoven fabric, a spun bonded melt blown melt blown spun bonded nonwoven fabric, a melt blown nonwoven fabric, a nonwoven nylon, a carded nonwoven fabric. 
     
     
         11 . The apparatus of  claim 1  wherein the at least one non-fluid compound is selected from the group consisting of granular compounds, particulate compound, powders, finely divided materials, and combinations thereof. 
     
     
         12 . The apparatus of  claim 1 , wherein the at least one non-fluid compound further comprises one or more of an odor-absorbing compound and a fragrance compound.