A structural member that contains a solid lineal profile that is formed from a plurality of consolidated ribbons is provided. Each of the ribbons includes unidirectionally aligned continuous fibers embedded within a thermoplastic polymer matrix. The continuous fiber ribbons are laminated together during pultrusion to form an integral solid profile having very high tensile strength properties. Contrary to conventional wisdom, the present inventors have discovered that careful control over certain aspects of the pultrusion process can allow such high strength profiles to be readily formed without adversely impacting the pultrusion apparatus.

A composite structure is fabricated by laying up at least one ply of fiber reinforcement and at least one layer of resin on a tool. The resin film layer is formed by laying strips of resin film. The fiber reinforcement is infused with resin from the resin layer.

The present invention is method for forming a sandwich structure having a pattern of particulate material enveloped between a carrier material and a cover material. The method allows accurate forming of pre-determined pattern at high production speed. Such a method is particularly useful in the manufacture of disposable absorbent articles, such as baby diapers.

A method of making a sandwich-type composite panel having a cellulose-based core and a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based cellular core disposed between the sheets and the skins. A pressure is applied to the stack after heating the stack wherein the skins are bonded to the core by the sheets to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with applying the pressure to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel. The heated first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge.

A method is disclosed for modifying the physical characteristics of a web which involves passing the web between at least one pair of interengaged rolls to incrementally stretch the web, and then withdrawing the incrementally stretched web from between the rolls under tension. A web modified according to the disclosed method has desirable breathability and liquid impermeability, as well as extensibility and a soft, cloth-like textured surface.

The present invention relates to a method of applying absorbent gelling material (AGM) granules by indirect printing onto an carrier layer for use in an absorbent article, particularly diaper for babies or adults, training pants, pull-up diapers (diaper pants), sanitary napkins, panty liners or the like. These articles typically comprise the carrier layer with the AGM particles together with further layers, making up the complete article.

A method for making an activatable material having a handling film layer thereon, comprising the steps of providing a continuous mass of a polymeric material having a longitudinal axis and being capable of adhering to a metal surface; applying a handling layer (e.g., film) over at least one side of the mass; forming stress relief indentations in the mass, with the handling layer at least partially extending into the indentations, wherein the stress relief indentations allow a resulting part to be applied in conforming geometry with a surface to which it is applied. The teachings also contemplate parts made by the above method and use thereof to bond to surfaces having a non-planar portion.

The present invention is directed to a novel process for preparing an absorbent article, wherein the process comprises providing a first sheet layer (2); conforming said first layer on a first roll C2, whereby longitudinal corrugations are formed on the layer; conforming said corrugated layer (2) on a second roll C3, whereby a pattern of pockets (4, 4a) is obtained; providing a pre-metered amount of SAP particulate material (6); providing a second sheet layer (7) material and affixing it for sandwiching with the first sheet layer; and finishing the absorbent article.

A method for making an activatable material having a handling film layer thereon, comprising the steps of providing a continuous mass of a polymeric material having a longitudinal axis and being capable of adhering to a metal surface; applying a handling layer (e.g., film) over at least one side of the mass; forming stress relief indentations in the mass, with the handling layer at least partially extending into the indentations, wherein the stress relief indentations allow a resulting part to be applied in conforming geometry with a surface to which it is applied. The teachings also contemplate parts made by the above method and use thereof to bond to surfaces having a non-planar portion.

The present invention is directed to a novel process for manufacturing an absorbent article comprising the steps of: providing a first sheet layer (2); providing an array of pockets (4, 4a) into said first sheet layer; providing a pre-metered amount of SAP particulate material (6); said pre-metered amount of SAP material being delivered from a rotating delivering drum (101, 111), said drum having apertures (103a, 103b, 103c, 103d, 113a, 113b, 113c) on its periphery corresponding to the array of pockets (4, 4a), said pre-metered amount of SAP material being delivered from the inner part of said drum (101, 111) through said apertures (103a, 103b, 103c, 103d, 113a, 113b, 113c); providing a second sheet layer (7) material and affixing it for sandwiching with the first sheet layer; finishing the absorbent article.