Laminated assembly, nappy comprising such an assembly and method for manufacturing such an assembly

Abstract

The invention relates to a laminated assembly including a support layer (32) and an anti-slip strip (34), the anti-slip strip (34) including an elastomeric material, the support layer (32) and the anti-slip strip (34) being laminated together, the anti-slip strip (34) including a base (34A) and a plurality of protruding elements (34B) extending from the base (34A) and the plurality of protruding elements (34B) protruding from a face (30A) of the laminated assembly (30). The invention also relates to a diaper including such a laminated assembly (30) and a process for manufacturing the laminated assembly (30). The invention also relates to a diaper including such an assembly and a process for manufacturing such an assembly.

Claims

1. A laminated assembly for a hygiene article comprising a support layer and an anti-slip strip, the anti-slip strip comprising an elastomeric material, the support layer and the anti-slip strip being laminated together, the anti-slip strip comprising a base and a plurality of protruding elements extending from the base and the plurality of protruding elements protruding from a face of the laminated assembly, wherein the anti-slip strip is free of openings.

2. The laminated assembly according to claim 1, wherein the support layer comprises a nonwoven web.

3. The laminated assembly according to claim 1, wherein the support layer comprises a thermoplastic film.

4. The laminated assembly according to claim 1, wherein the support layer comprises an elastic film comprising a thermoplastic material, the base of the anti-slip strip and the elastic film each having a width, the width of the base being less than the width of the elastic film.

5. The laminated assembly according to claim 4, wherein the width of the base is greater than or equal to 10% of the width of the elastic film and less than or equal to 60% of the width of the elastic film.

6. The laminated assembly according to claim 1, wherein the support layer comprises a first nonwoven web, a second nonwoven web and an elastic film comprising a thermoplastic material, the elastic film being laminated between the first and second nonwoven webs.

7. The laminated assembly according to claim 1, wherein, at rest, in a zone comprising the protruding elements, the anti-slip strip has a coefficient of static friction, measured according to standard ASTM D1894, in a machine direction and/or a direction perpendicular to the machine direction, greater than or equal to 0.1 and less than or equal to 10.

8. The laminated assembly according to claim 7, wherein, at rest, in the zone comprising the protruding elements, the anti-slip strip has a coefficient of static friction, measured according to standard ASTM D1894, in the direction MD and/or the direction CD, greater than or equal to 0.8 and less than or equal to 3.

9. The laminated assembly according to claim 1, wherein the anti-slip strip has a coefficient of static friction, measured according to standard ASTM D1894, when the anti-slip strip is stretched to 15% of a rest value, comprised between 50% and 150% of the coefficient of static friction at rest.

10. The laminated assembly according to claim 1, wherein, at rest, the plurality of protruding elements has a protruding element density greater than or equal to 3 protruding elements per cm.sup.2, and less than or equal to 400 protruding elements per cm.sup.2.

11. The laminated assembly according to claim 10, wherein, at rest, the plurality of protruding elements has a protruding element density greater than or equal to 10 protruding elements per cm.sup.2, and less than or equal to 300 protruding elements per cm.sup.2.

12. The laminated assembly according to claim 1, wherein, at rest, the plurality of protruding elements have a pattern comprising a repetition of a slip-resistant strip pattern.

13. The laminated assembly according to claim 1, wherein a sum of areas defined on the base by orthogonal projections of protruding elements on the base is greater than or equal to 1% of the total area of the base of an anti-slip strip pattern, and less than or equal to 40% of the total area of the base of the anti-slip strip pattern.

14. The laminated assembly according to claim 13, wherein the sum of the areas defined on the base by the orthogonal projections of protruding elements on the base is greater than or equal to 5% of the total area of the base of the anti-slip strip pattern, and less than or equal to 35% of the total area of the base of the anti-slip strip pattern.

15. The laminated assembly according to claim 1, wherein the base has a thickness greater than or equal to 10 μm, and less than or equal to 200 μm.

16. The laminated assembly according to claim 1, wherein the protruding elements are pins and/or studs and/or stems, each stem having a head disposed at an end of the stem opposite the base.

17. An absorbent article comprising a laminated assembly according to claim 1.

18. The laminated assembly of claim 1, wherein the anti-slip strip comprises a thermoplastic elastomeric material.

19. The laminated assembly of claim 1, wherein a width of the base is less than a width of an elastic film of the support layer, the elastic film is present in a portion of an elastic ear of the hygiene article, and a length of the base is greater than the width of the base.

20. A process for manufacturing a laminated assembly for a hygiene article, the process comprising following steps: forming an anti-slip strip comprising a base and a plurality of protruding elements extending from the base by distributing an elastomeric material in a molding device; assembling a support layer and the anti-slip strip by laminating the support layer and the anti-slip strip, wherein the anti-slip strip is free of openings.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features and advantages of the subject matter of the present disclosure will become apparent from the following description of embodiments, given by way of non-limiting examples, with reference to the appended figures, wherein:

(2) FIG. 1 is a schematic view of a diaper;

(3) FIG. 2A is a schematic cross-sectional view, according to the plane II-II of FIG. 1, of a laminated assembly according to a first embodiment;

(4) FIG. 2B is an exploded schematic cross-sectional view of a support layer;

(5) FIGS. 3 to 5 are schematic cross-sectional views of a laminated assembly according to other embodiments;

(6) FIG. 6 is a schematic cross-sectional view of an anti-slip strip;

(7) FIG. 7 is a partial schematic cross-sectional view of a laminated assembly according to another embodiment;

(8) FIGS. 8A-8F are schematic cross-sectional and top views of the different embodiments of the anti-slip strip;

(9) FIG. 9 is a partial schematic view of the top of a molding strip;

(10) FIGS. 10 and 11 are schematic cross-sectional views of the molding strip in FIG. 9;

(11) FIG. 12 is an enlarged schematic view of a pattern of a zone XII of the molding strip in FIG. 9;

(12) FIG. 13 is a schematic view of a pattern of elements of a molding strip according to another embodiment;

(13) FIG. 14 is a partial schematic cross-sectional view according to the plane XIV-XIV of the molding strip in FIG. 13;

(14) FIGS. 15-18 are schematic views of molding strip patterns according to other embodiments;

(15) FIG. 19 shows a partial schematic cross-sectional view according to the plane XIX-XIX of the molding strip to form the pattern of FIG. 18;

(16) FIG. 20 is a schematic representation of an example of an apparatus for producing an anti-slip strip;

(17) FIGS. 21 to 23 are schematic representations of examples of apparatus for producing a laminated assembly;

(18) FIGS. 24A-24C are schematic representations of laminated assemblies;

(19) FIG. 25 is a schematic representation of a test specimen;

(20) FIG. 26 is a schematic representation of a piece of equipment used to perform elongation at break and/or set measurement;

(21) FIG. 27 is a graph representing the elongation at break curves of a laminated assembly including an anti-slip strip and a laminated assembly without such an anti-slip strip;

(22) FIG. 28 is a schematic representation of an example of an apparatus for producing an anti-slip strip including a forming device;

(23) FIG. 29 is a top view of an anti-slip strip illustrating the edge properties of this strip.

(24) In all the figures, the elements in common are identified by identical numerical reference marks.

DETAILED DESCRIPTION

(25) FIG. 1 is a highly schematic representation of a diaper 10, for example a disposable diaper. The diaper 10 consists of an absorbent central portion 12 and a front waistband 14 with two front ears 16 and a back waistband 18 with two back ears 20 for attaching the diaper 10 to the diaper's wearer. Each back ear 20 is generally provided with an retaining device 22, for example with hooks, which cooperates with a application zone 24 arranged on the front waistband 14. In the hygiene field, this application zone 24 is commonly referred to as the “landing zone” or in French to the “bande confort”.

(26) FIG. 2A shows a first embodiment of a laminated assembly 30 that may be used to make a front ear 16 and/or back ear 20 for a diaper 10.

(27) Hereinafter the term laminated assembly will refer to both the uncut laminated assembly and the laminated assembly cut to form the front ear 16 and/or back ear 20 of a diaper 10.

(28) The laminated assembly 30 is shown in FIG. 2A in a cross-sectional view according to the sectional plane II-II of FIG. 1.

(29) The laminated assembly 30 extends in a longitudinal direction X and a lateral direction Y, orthogonal to the longitudinal direction X. The cross-sectional view of FIG. 2A is in the sectional plane YZ, the transverse direction Z being orthogonal to the plane XY and defining the thickness direction of the laminated assembly 30. The directions XYZ are orthogonal to each other.

(30) The laminated assembly 30 in FIG. 2A consists of a support layer 32 and an anti-slip strip 34. The support layer 32 and the anti-slip strip 34 extend in the longitudinal direction X and the lateral direction Y. The laminated assembly 30 consists of an upper face 30A and a lower face 30B.

(31) In the embodiment shown in FIG. 2A, the support layer 32 consists of a first nonwoven web 36, a second nonwoven web 38 and an elastic film 40, joined together with the adhesive 42. The elastic film 40 is joined between the first nonwoven web 36 and the second nonwoven web 38 by laminating the first and second nonwoven webs 36, 38, the elastic film 40 and the adhesive 42.

(32) As shown in FIG. 6, the anti-slip strip 34 includes a base 34A and a plurality of protruding elements 34B. The base 34A has an upper face 34AA and a lower face 34AB and the protruding elements 34B extend from the base 34A, in particular from the upper face 34AA of the base 34A. In the lateral direction Y, the base 34A has a width L34A and the protruding elements 34B have a width L34B. The width L34B of the protruding elements 34B is measured in the lateral direction Y between two lines parallel to the longitudinal direction X and to the edges of the base 34A and which include all the protruding elements 34B being tangential to the protruding elements 34B. In the embodiment of FIG. 6, the width L34A of the base 34A is greater than the width L34B of the projecting elements 34B, i.e. the width L34B of the projecting elements 34B is less than or equal to the width L34A of the base 34A.

(33) The protruding elements 34B protrude from the upper face 30A of the laminated assembly 30.

(34) The protruding elements 34B may form an anti-slip strip pattern 44 on the anti-slip strip 34, i.e. the base 34A, in particular the upper face 34AA of the base 34A, may have zones 46 with no protruding elements 34B and a zone of the anti-slip strip 34 with protruding elements 34B forming the anti-slip strip pattern 44. The anti-slip strip pattern 44 may be single or may be repeated several times on the anti-slip strip 34 in the longitudinal direction X and/or the lateral direction Y. The anti-slip strip pattern 44 may include a closed contour.

(35) The base 34A has a thickness E34A in the transverse direction Z and the protruding elements 34B have a height H34B in the transverse direction Z. The height H34B of a protruding element 34B is measured perpendicularly to the upper face 34AA of the base, between the base and a point of the protruding element 34B furthest from the upper face 34AA of the base 34A.

(36) The plurality of protruding elements 34B may include protruding elements 34B having different heights H34B and/or different widths L34BB measured in a plane parallel to the plane XY. The width L34BB is measured at the location of the projecting element having a maximum width.

(37) The protruding elements 34B may be pins and/or studs and/or stems, each stem having a head arranged at an end of the stem opposite the base 34A. The protruding elements 34B may be of a single type for a given anti-slip strip 30 or may be a mixture of one or more types of protruding elements 34B.

(38) As shown in FIG. 7, the anti-slip strip 34 includes pins 34BB having a height H34B in the transverse direction Z and a width L34BB in a plane parallel to the plane XY. In FIG. 7, only one pin 34BB has been shown. The pin 34BB has a height H34B greater than or equal to the width L34BB. When the height H34B is less than the width L34BB, it is referred to as a pin. The anti-slip strip 34 is laminated with a support layer 32, formed in this embodiment by a nonwoven web, part of the fibers of which have penetrated the base 34A of the anti-slip strip. It is therefore understood that the assembly of the support layer 32 and of the anti-slip strip 34 has been carried out before complete solidification of the base 34A of the anti-slip strip 34 so as to cause the support layer 32 to penetrate at least partially into the base 34A. As shown in FIG. 7, an anti-slip strip 34 and a support layer 32 including a nonwoven are shown. This nonwoven may form a front ear 16 and/or a back ear 20 for a diaper 10, in particular the anti-slip strip 34 may be arranged on the front ear 16 in such a way that the protruding elements extend towards the absorbent part of the absorbent article and/or extend away from the absorbent part of the absorbent article.

(39) Protruding elements including a stem surmounted by a head are shown in FIGS. 20 to 23.

(40) FIG. 2B is an exploded view of two support layers 32 according to FIG. 2A and shows a possible way of joining the support layer 32. In FIG. 2B, two support layers 32 are shown joined together. In order to form the support layer 32, after the nonwoven webs, the elastic film and the adhesive films have been laminated together, the entire FIG. 2B is cut in the middle to form two support layers 32.

(41) In the embodiment shown in FIG. 2B, the support layer 32 consists of a first nonwoven web 36 and a second nonwoven web 38. The first and second nonwoven webs 36, 38 may be of the same or different nature.

(42) In the embodiment of FIG. 2B, the first and second nonwoven webs 36, 38, each include non-activated zones 36A, 38A and activated zones 36B, 38B prior to assembly.

(43) In the embodiment of FIG. 2B, the dimension in the lateral direction Y of the activated zones 36B, 38B are equal. They could be different from one web to another and/or within the same web. The first and second nonwoven webs 36, 38 may also have no activated zones, as the activation of the support layer is achieved after bonding with the elastic film 40.

(44) The adhesive 42 is applied to the first and second nonwoven webs 36, 38. The adhesive 42 is arranged in solid strips 42A and in thin lines 42B. The adhesive 42 thus forms a plurality of lines of adhesive 42B, for example continuous in longitudinal direction X. The elastic film 40 has a width L40. The width L34A of the base 34A of the anti-slip strip 34 is less than the width L40 of the elastic film 40. In the example in FIG. 2A, the width L34A of the base 34A of the anti-slip strip 34 corresponds to 25% of the width L40 of the elastic film 40.

(45) The anti-slip strip 34 may be bonded and/or ultrasonically welded to the upper face 30A of the support layer 32. The anti-slip strip 34 may also be joined by laminating the anti-slip strip 34 prior to complete solidification of the base 34A of the anti-slip strip 34 so as to cause the support layer 32 to penetrate at least partially into the base 34A, in the manner shown in FIG. 2A, the second nonwoven web 38.

(46) The anti-slip strip 34 may be manufactured, for example, using an apparatus 100 as shown in FIG. 20. The apparatus 100 allows the manufacture of an anti-slip strip 34 for a laminated assembly 30. The anti-slip strip 34 includes the continuous base 34A and the plurality of protruding elements 34B. In the embodiment of FIG. 20, each protruding element 34B includes a stem 48 surmounted by a head 50. The head 50 is arranged at an end of the protruding element 34B opposite the base 34A, in particular at the upper face 34AA of the base 34A.

(47) The apparatus 100 as shown includes a molding strip 102 positioned on rotary drive means 104 including two rollers 104A, 104B, a material distribution means 106, for example an injector, adapted to carry out an injection of elastomeric molding material.

(48) The assembly formed by the molding strip 102 and the rotary drive means 104 thus forms a molding device.

(49) The illustrated example including two rollers 104A, 104B is not exhaustive, the number and arrangement of the roller(s) may vary in particular to adapt to the length of the molding strip 102 and the different stations of the apparatus. For example, three rollers could be used, or even a single roller so that the molding strip is arranged on the periphery of the single roller, such molding strip forming a sleeve. In particular, only one of the two rollers may be driven in rotation by motorized means, for example the roller 104A, the other roller 104B being free, i.e. without motorized means, and driven in rotation via the molding strip, itself driven by the roller 104A. The direction of travel of the molding strip defines the direction MD of the anti-slip strip.

(50) The molding strip 102 as shown includes an inner face 102A and an outer face 102B, the inner face 102A being in contact with the rotary drive means 104.

(51) The material distribution means 106 is arranged so as to inject molding material onto the outer face 102B of the molding strip 102.

(52) Specifically, the material distribution means 106 is arranged opposite the molding strip 102, spaced from the molding strip 102 so as to define an air gap e shown in FIG. 20, wherein the boundary of the material injected onto the outer face 102B of the molding strip 102 is marked by the reference A, corresponding to the trailing edge of the material injected onto the molding strip 102 with respect to the direction of travel of the molding strip 102.

(53) The molding strip 102 is provided with a plurality of cavities 102C allowing the realization of the protruding elements 34B of the anti-slip strip 34.

(54) The cavities 102C are each formed so as to define a stem 102C1 extending from the outer face 102B to the inner face 102A of the molding strip 102 and a head 102C2 extending between the stem 102C1 and the inner face 102A of the molding strip 102.

(55) In the example shown, the heads 50 of the cavities 102C open onto the inner face 102A of the molding strip 102. The cavities 102C are therefore through-going. The cavities 102C may also be blind, i.e. they do not open out from the inner face 102A of the molding strip 102, and/or cavities 102C may have only one stud or pin.

(56) The portions of the cavities 102C forming the stems 102C1 typically extend in a direction perpendicular to the outer face 102B of the molding strip 102. The portions of the cavities 102C forming the stems 102C1 typically have a rotational geometry about an axis perpendicular to the outer face 102B of the molding strip 102, or a geometry having a plane of symmetry extending in a direction parallel to the direction of travel of the molding strip 102 and/or in a direction perpendicular to the direction of travel of the molding strip 102.

(57) The portions of the cavities 102C forming the heads 102C2 typically extend radially or transversely with respect to an axis perpendicular to the outer face 102B of the molding strip 102, and may be rotationally symmetrical about this axis perpendicular to the outer face 102B of the molding strip 102. The portions of the cavities 102C forming the heads 102C2 typically have a substantially frustoconical or hexahedral shape.

(58) The portions of the cavities 102C forming the heads 102C2 may be linear or curved, for example to form curved portions towards the inner face 102A or towards the outer face 102B of the molding strip 102 extending from the portions of the cavities 102C forming the stems 102C1.

(59) The portions of the cavities 102C forming the heads 102C2 may have a constant or variable thickness.

(60) In the example shown in the figures, the portions of the cavities 102C forming the heads 102C2 extend radially around the portions of the cavities 102C forming the stems 102C1, and are generally disc-shaped.

(61) The molding strip 102 may have on its inner face 102A or on its outer face 102B a particular texture such as grooves, groove pattern or vent or pin pattern, or be substantially smooth, for example as described in application WO2017187103, incorporated by reference.

(62) The molding strip 102 may be formed by superimposing several strips, and is therefore not necessarily a single piece or material.

(63) The material distribution means 106 is typically arranged so as to carry out the injection of molding material into the molding strip 102 at a section of the molding strip 102 where the latter is supported against a drive roller, in this case the drive roller 104A in the example shown in FIGS. 20 and/or 21. The drive roller then forms a bottom for the cavities 102C.

(64) In the case where the injection of molding material is carried out while the molding strip 102 is not supported against a drive roller, the material distribution means 106 may then include a base disposed on the other side of the molding strip 102, so that the inner face 102A of the molding strip 102 is supported against the base when the injection of material is carried out, the base then forming a bottom for the cavities 102C of the molding strip 102.

(65) The use of a molding strip 102 in combination with drive means 104 compared with the use of conventional forming means such as rollers in which molding cavities are directly formed is advantageous for several reasons.

(66) The use of a molding strip 102 is of particular interest in terms of modularity. The molding strip may in fact be easily removed and replaced from the drive means, unlike a massive roller for which disassembly and reassembly operations are particularly complex to carry out. Such an advantage is particularly noticeable when the two rollers 104A, 104B are fixed to a frame on the same side, leaving the end of the other side free to introduce/remove the molding strip. A means of guiding the molding strip may also be used to facilitate the insertion and/or removal of the molding strip. A guide means may include a tensioning element for the molding strip.

(67) Moreover, the production of a molding strip is greatly simplified compared with the production of a roller with molding cavities. Such rollers are in fact typically made by stacking successive slices, thus requiring multiple machining operations and leading to significant constraints during assembly and at each change of reference of protruding elements, and have a large mass requiring the holding of these rollers by their two ends, which consequently complicates their replacement.

(68) The cavities 102C in the molding strip 102 may be produced by an etching process or by using a laser where it is desired to form protruding elements 34B. It may also be envisaged to produce the molding strip 102 with cavities 102C distributed evenly over the entire molding strip 102 and then fill in the cavities 102C where it is desired to form zones 20 without projections 34B. A molding strip made of for example nickel or stainless steel or non stainless steel could be used.

(69) The separation between the anti-slip strip 34 and the molding strip 102 is marked in FIG. 20 by the reference C, for example the point at which the base 34A of the anti-slip strip 34 is no longer in contact with the molding strip 102. It may be provided that the molding strip 102 is loaded onto the release roller 108, i.e. the release roller 106 forms a lever in the molding strip 102 to facilitate the release of the protruding elements from the mold.

(70) In the example shown, the cavities 102C of the molding strip 102 are through-going. The apparatus may then include an element, such as a doctor blade 110, positioned to scrape the inner face 102A of the molding strip 102 to remove excess molding material if necessary. Injection means the action of shaping a molten molding material, for example, dispensing, feeding, molding, injecting, extruding.

(71) The anti-slip strip 34 may thus be formed by distributing the elastomeric material by the material distribution means 106 into the cavities 102C of the molding strip 102 and against the outer face 102B of the molding strip 102. The molding strip 102 of FIG. 20 has cavities 102C, each cavity being formed to define a stem 102C1 extending from the outer face 102B to the inner face 102A of the molding strip 102 and a head 102C2 extending between the stem 102C1 and the inner face 102A of the molding strip 102. The molding strip 102 may include cavities 102 having no portion for defining a head 102C2. The cavities 102C of the molding strip 102 may also be non-through cavities and therefore not open to the inner face 102A of the molding strip 102.

(72) Protruding elements including a stem surmounted by a head are shown in FIG. 28. These protruding elements are obtained by calendering the protruding elements shown in FIGS. 20 to 23 with a forming device 120 including a drive roller 122 and a forming roller 124.

(73) When symmetrical and flat heads 50 are desired, the speeds of the drive roller 122 and forming roller 124 are identical.

(74) When asymmetrical heads 50 are to be formed, the speeds of drive roller 122 and forming roller 124 are different. In particular, the following ratio V122/V124=A may be used, with A greater than or equal to 0.4, preferably greater than or equal to 0.65 and less than or equal to 1.6, preferably less than or equal to 1.35.

(75) Examples of the anti-slip strip 34 are shown in FIGS. 8A-8F. As can be seen, not all protrusions 34B have a uniform height H34B and may have different widths L34BB (see in particular the embodiment of FIG. 8E). It can also be seen that the projecting elements 34B generally form an anti-slip strip pattern 44 which is repeated in the longitudinal direction X (see FIGS. 8A-8F). The anti-slip strip pattern extends over the entire width L34A of the base 34A of the anti-slip strip 34, i.e. the dimension of the anti-slip strip in the lateral direction Y or the direction CD. However, the anti-slip strip 34 may also have no repeating pattern and be formed of a single anti-slip strip pattern, as shown in FIG. 8F. The protruding elements 34B may form an anti-slip strip pattern 44 with a closed contour 44A. The protruding elements 34B may have a different density in the longitudinal direction X and the lateral direction Y and/or along the longitudinal direction X and/or the lateral direction Y.

(76) The support layer 32 may then be joined with the anti-slip strip 34 by means of adhesive, ultrasonic welding, and/or by melting the base 34A or support layer 32.

(77) The apparatus presented above and the associated process may also have means and a step for assembling a support layer 32 to the base 34A.

(78) In order to carry out the assembly of the support layer 32 to the base 34A of the anti-slip strip 34, the proposed apparatus 100 may include means for driving the support layer 32, adapted to carry out a tape feed and to apply the support layer 32 against the underside 34AB of the base 12 downstream of the material distribution means 106.

(79) FIGS. 21 and 22 schematically show an example of apparatus 100 including such means. FIG. 22 is a detailed view of the zone XXII of FIG. 21.

(80) The apparatus as illustrated is similar to that previously shown with reference to FIG. 20; the common elements are therefore not described again here.

(81) As can be seen in FIGS. 20 and 21, the apparatus as shown includes web drive means 112, here consisting of two rollers 112A, 112B, configured to provide a feed of the support layer 32 downstream of the material distribution means 106. In this embodiment, the direction MD of the anti-slip strip 34 is merged with the direction MD of the support layer 32.

(82) The support layer 32 is typically a layer of nonwoven material, a thermoplastic film, an elastic film or a composite film, or an assembly of thermally consolidated fibers and/or filaments.

(83) In the example shown in FIGS. 20 and 21, the support layer 32 is shown as a nonwoven web.

(84) The drive means 112 of the support layer 32 are configured to feed the support layer 32 to the apparatus, and apply this support layer 32 against the lower face 34AB of the base 34 downstream of the material distribution means 106.

(85) The drive means 112 are configured so that this application is carried out prior to the complete solidification of the base 34A. Thus, this application results in at least partial penetration of the support layer 32 beyond a plane defined by the lower face 34AB of the base 34. The point of contact between the base 34A and the support layer 32 is marked by reference B in the figures.

(86) More precisely, the lower face 34AB of the base 34 is substantially flat, and defines a plane. The application of the support layer 32 against this lower face 34AB causes portions of the support layer 32, for example fibers and/or filaments of the nonwoven web, in the case where the support layer 32 is a nonwoven web, to penetrate into the base 34A, thereby penetrating the lower face 34AB of the base 34A.

(87) Since such application is carried out prior to the complete solidification of the base 34A, it is not necessary to heat the base 34A and/or the support layer 32 in order to achieve such a bond.

(88) By way of example, considering a base 34A made of VISTAMAXX 7050 FLX (available from ExxonMobil Chemical, Houston, Tex.), the application of the substrate against the lower face 34AB of the base 34A is typically performed when the lower face 34AB of the base 34A has a temperature comprised between the melting temperature of the material and the Vicat B softening temperature of the constituent material minus 30° C. or between the melting temperature of the constituent material and the Vicat A softening temperature of the constituent material. More particularly, when the base comprises a polyolefin-based material, the lower face 34AB of the base 34A has a temperature comprised between 150° C. and 200° C., typically of the order of 175° C., this temperature being typically measured by means of an infrared or laser camera. The VICAT softening temperature is defined as the temperature obtained according to one of the methods described in standards ISO 306 or ASTM D1525 with a heating rate of 50° C./h and a standard load of 50 N for VICAT B and a standard load of 10 N for VICAT A.

(89) The support layer 32 may be applied uniformly or non-uniformly against the lower face 34AB of the base 34A.

(90) The bond between the support layer 32 and the base 34A may be uniform or non-uniform.

(91) In the case where the support layer 32 is a thermally consolidated set of fibers and/or filaments, bonding to the base 34A is also achieved by penetration into the base 34A of some of the fibers and/or filaments of the support layer 32.

(92) If the support layer 32 is a nonwoven web, the protruding elements may be easily removed from the mold even with a nonwoven with a weight of less than 80 g/m.sup.2 (material mass in grams per square meter of nonwoven). By way of example, the weight of the nonwoven may be comprised between 5 g/m.sup.2 and 120 g/m.sup.2, or between 25 g/m.sup.2 and 100 g/m.sup.2, or between 10 g/m.sup.2 and 70 g/m.sup.2.

(93) This method of joining a support layer 32 to a base 34A including protruding elements 34B is particularly advantageous in that it does not cause deformation of the base 34A, and therefore advantageously makes it possible to retain the shape of the base 34A obtained during the injection step, and in particular to retain the straight edges obtainable by the process and apparatus described above.

(94) In the case where the support layer 32 is a nonwoven web, the apparatus may include a calendering device upstream of the drive means 112, thus making it possible to carry out a step of calendering locally or not of the nonwoven web prior to its application against the base 34A.

(95) The apparatus 100 of FIGS. 21 and 22 may be used to laminate the anti-slip strip 34 and the support layer 32, where the support layer 32 may include one or more nonwoven webs with or without thermoplastic film (elastic or non-elastic), such as for example the support layer 32 in FIG. 2A.

(96) The apparatus 100 of FIGS. 21 and 22 may also be used to join the anti-slip strip 34 to the second nonwoven web 38 of FIG. 2A, the second nonwoven web 38 and the anti-slip strip 34 being then joined to the elastic film 40 and the first nonwoven web 36 of FIG. 2A.

(97) The embodiment of FIG. 3 differs from the embodiment of FIG. 2A, in particular in that the anti-slip strip 34 passes through the second nonwoven web 38, with the protruding elements 34B projecting from the upper face 30A of the laminated assembly 30.

(98) In this embodiment, the anti-slip strip 34 is formed by distributing the elastomeric material in the cavities 102C of the molding strip 102 through the second nonwoven web 38. The apparatus 100 includes, as for the apparatus of FIG. 23, drive means 114 configured to provide a feed of the second nonwoven web 38 upstream of the material distribution means 106. The anti-slip strip 34 being injected through the second nonwoven web 38, causing portions of the second nonwoven web 38 to penetrate into the base 34A. In FIG. 23, for reasons of simplicity, the second nonwoven web 38 has been shown with a lower thickness than the thickness shown for the first nonwoven web 36. The thickness of the first and second nonwoven webs 36, 38 could be similar or different depending on the application.

(99) Since such application is carried out prior to the complete solidification of the base 34A, it is not necessary to heat the base 34A and/or the support layer 32 in order to achieve such a bond.

(100) The second nonwoven web 38 and the anti-slip strip 34 are then joined to the elastic film 40 and the first nonwoven web 36 in FIG. 3. The base material and the elastic film material may be the same or different but still be elastomeric materials.

(101) In the embodiment of FIG. 4, the elastic film 40 is made of elastomeric material. The elastomeric material of the elastic film is, for example, the same as the elastomeric material of the anti-slip strip, and the first and second nonwoven webs 36, 38 are laminated to the elastic film 40 without the addition of adhesive.

(102) Typically, the first and second nonwoven webs 36, 38 may be bonded to the elastic film 40 prior to complete solidification of the elastic film 40 by applying the first nonwoven web 38 against the lower face 34AB of the base 34A and the second nonwoven web 36 against the upper face 34AA of the base 34A, causing portions of the first and second nonwoven webs 36, 38 to penetrate into the base 34A.

(103) Since such application is carried out prior to the complete solidification of the base 34A, it is not necessary to heat the base 34A and/or the support layer 32 in order to achieve such a bond. The material of the base and the material of the elastic film may be the same or different but still be elastomeric materials. According to an alternative embodiment not shown, the first nonwoven web could be bonded to the elastic film via an adhesive layer (continuously and/or in the form of adhesive lines, for example as shown in FIG. 3).

(104) The apparatus 100 of FIG. 23 includes drive means 112, 114 respectively configured to provide a feed of the first nonwoven web 36 downstream of the material distribution means 106 and to provide a feed of the second nonwoven web 38 upstream of the material distribution means 106.

(105) When the elastomeric material of the anti-slip strip 34 is different from the elastomeric material of the elastic film 40 or when the film 40 is a non-elastic thermoplastic film, the apparatus of FIG. 23 includes a second material distribution means arranged downstream of the material distribution means 106.

(106) In the embodiment of FIG. 5, the second nonwoven web 38 is assembled by bonding by means of an adhesive 42 to the elastic film 40. The second nonwoven web 38 is in two parts, each part being arranged on either side of the anti-slip strip 34. The base material and the material of the elastic film may be the same or different but still be elastomeric materials. According to an alternative embodiment not shown, the first nonwoven web could be bonded to the elastic film via an adhesive layer (continuously and/or in the form of adhesive lines, for example as shown in FIG. 3).

(107) In the embodiments of FIGS. 2 to 4, the anti-slip strip is arranged in the middle in the lateral direction Y of the support layer 32. In the embodiment of FIG. 5, the anti-slip strip is not centered.

(108) The anti-slip strip 34 may be placed at different positions on the support layer 32 as shown in FIGS. 24A-24B. The anti-slip strip may be placed in any position intermediate between the positions shown in FIGS. 24A-24C. In FIGS. 24A-24C, the anti-slip strip 34 has a dimension in the direction MD which is larger than a dimension in the direction CD, it is understood that the anti-slip strip has a length in the direction MD and a width in the direction CD.

(109) The molding strips 102 of FIGS. 20 to 23 have cavities 102C, each cavity being formed to define a stem 102C1 extending from the outer face 102B to the inner face 102A of the molding strip 102 and a head 102C2 extending between the stem 102C1 and the inner face 102A of the molding strip 102. The molding strip 102 may include cavities 102 having no portion for defining a head 102C2. The cavities 102C of the molding strip 102 may also be non-through cavities and therefore not open to the inner face 102A of the molding strip 102.

(110) FIGS. 9 to 19 show molding strips 102 for forming anti-slip strips 34 with various patterns.

(111) FIG. 9 is a partial view of a molding strip 102 whose width L102 in the lateral direction Y is greater than the width L34B of the protruding element pattern 34B. The molding strip 102 is seen from the outer face 102B. FIG. 10 is a cross-sectional view according to the sectional plane X-X of FIG. 9 and FIG. 11 is an enlargement XI of FIG. 10 showing the molding cavities 102C of the molding strip 102. FIG. 12 is an enlarged view of FIG. 9 showing the cavities 102C of the molding strip 102. Note that in the embodiment of FIG. 9, the perforated portion of the molding strip 102 is not centered with respect to the axis of symmetry A of the molding strip 102. The perforated part of molding strip 102, corresponding to the width L34B of the protruding elements 34B on the base 34A of the anti-slip strip 34 could be centered on the axis of symmetry A or even offset to the left or right of FIG. 9.

(112) For example, the anti-slip strip 34 obtained by distributing elastomeric material with the molding strip 102 in FIGS. 9 to 12 is an anti-slip strip with a width L34A measured in the lateral direction Y equal to 20 mm. Taking the full width L34A of the anti-slip strip, a zone of 22.52 mm.sup.2 comprises 49 protruding elements 34B, i.e. a density of 217.616 protruding elements per cm.sup.2, representing 13.40% of the total area of the base 34A.

(113) FIG. 13 is a view of molding strip 102 similar to the view in FIG. 12 and FIG. 14 is a cross-sectional view along the plane XIV similar to the view in FIG. 11 for the pattern in FIG. 13. FIG. 13 shows a “flower” pattern of the cavities 102C of the molding strip 102. As shown in FIG. 14, the cavities 102 may have a draft, here an angle α of 10° or less, to facilitate the removal of protruding parts from the mold.

(114) For example, the anti-slip strip 34 obtained by distributing elastomeric material with the molding strip 102 in FIGS. 13 and 14 is an anti-slip strip whose width L34A measured in the lateral direction Y is equal to 20 mm. Taking the full width L34A of the anti-slip strip, a zone of 130 mm.sup.2 comprises 30 protruding elements 34B, i.e. a density of 23.077 protruding elements per cm.sup.2, representing 29.05% of the total area of the base 34A.

(115) FIGS. 15 to 19, which are similar views to the view in FIG. 12, show other patterns formed by the cavities 102C of the molding strips 102. FIG. 19 is a similar view to the view in FIG. 14 for the pattern in FIG. 18. As can be seen, the cavities 102C are not continuous and do not have a uniform depth. The cavities 102C have three different heights H102C1, H102C2, H102C3.

(116) For example, the anti-slip strip 34 obtained by distributing elastomeric material with the molding strip 102 in FIG. 15 is an anti-slip strip with a width L34A measured in the lateral direction Y equal to 20 mm. Taking the full width L34A of the anti-slip strip, a zone of 110 mm.sup.2 comprises 11 protruding elements 34B, i.e. a density of 10 protruding elements per cm.sup.2, representing 25.15% of the total area of the base 34A.

(117) For example, the anti-slip strip 34 obtained by distributing elastomeric material with the molding strip 102 in FIG. 16 is an anti-slip strip with a width L34A measured in the lateral direction Y equal to 20 mm. Taking the full width L34A of the anti-slip strip, a zone of 382.78 mm.sup.2 comprises 225 protruding elements 34B, i.e. a density of 58.78 protruding elements per cm.sup.2, representing 8.11% of the total area of the base 34A.

(118) For example, the anti-slip strip 34 obtained by distributing elastomeric material with the molding strip 102 in FIG. 17 is an anti-slip strip with a width L34A measured in the lateral direction Y equal to 20 mm. Taking the full width L34A of the anti-slip strip, a zone of 251.66 mm.sup.2 comprises 405 protruding elements 34B, i.e. a density of 160.93 protruding elements per cm.sup.2, representing 9.91% of the total area of the base 34A.

(119) For example, the anti-slip strip 34 obtained by distributing elastomeric material with the molding strip 102 in FIG. 18 is an anti-slip strip with a width L34A measured in the lateral direction Y equal to 20 mm. Taking the full width L34A of the anti-slip strip, a zone of 187.35 mm.sup.2 comprises 35 protruding elements 34B, i.e. a density of 18.682 protruding elements per cm.sup.2, representing 25.22% of the total area of the base 34A.

(120) As shown in FIG. 29, the anti-slip strip 34 is obtained by injecting elastomeric material into the molding strip 102, so the anti-slip strip 34 extends in the longitudinal direction X in FIG. 29. The lateral direction Y is also shown in FIG. 29. Here the longitudinal direction X is parallel to the machine direction MD, i.e. the direction of travel of the anti-slip strip 34.

(121) Two edges B are defined for this anti-slip strip 34, each extending in the longitudinal direction X, these two edges B defining the two ends of the base 34A of the anti-slip strip 34 in the lateral direction Y, orthogonal to the longitudinal direction X.

(122) The protruding elements are generally arranged close to the edges B, for example at a distance D from the edges B comprised between 2 and 3 pitches P of protruding elements, typically equal to 2 or 3 pitches P, the distance D being measured in the lateral direction Y in relation to the longitudinal direction X. The pitch P between two protruding elements corresponds to the distance between two successive protruding elements in the longitudinal direction. In the example shown in FIG. 29, the protruding elements are arranged in columns extending in the longitudinal direction X, these columns being repeated identically in the lateral direction Y. The protruding elements may also be arranged in a staggered or “honeycomb” arrangement, for example by shifting the columns of the protruding elements in the longitudinal direction.

(123) As shown in FIG. 29, each of the edges B has a succession of hills and valleys, said succession extending in the longitudinal direction L and said hills and valleys extending in a plane parallel to that formed by the base 34A of the anti-slip strip 34, said hills and valleys reflecting slight irregularities in the distribution of molding material for the formation of the anti-slip strip 34, it being understood that a perfectly straight edge is not industrially feasible.

(124) Valleys are understood to be the regions of the edges B protruding inwardly from the anti-slip strip 34, whereas hills are understood to be the regions of the edges B protruding outwardly from the anti-slip strip 34.

(125) The regularity of the edges B may thus be evaluated by virtue of these successive hills and valleys.

(126) The edges B have, when viewed in section in a direction transverse to the longitudinal direction, a portion with a rounded shape. In particular, the rounded shape is oriented to the lateral outside of the base 34A. This rounded shape is produced when forming the base 34A. In other words, this rounded shape was not obtained by cutting.

(127) The apparatus and the process as presented above make it possible to obtain edges B of the anti-slip strip 34 such that for a length L in the longitudinal direction L corresponding to three consecutive hills, the maximum distance E between the hills and valleys in the lateral direction Y, orthogonal to the longitudinal direction X is less than 3 mm, or more precisely less than 2 mm, or more precisely less than 1 mm, or comprised between 0.001 mm and 1 mm, more particularly between 0.001 mm and 0.5 mm, more particularly between 0.001 mm and 0.1 mm.

(128) Such a definition is also applicable for a length corresponding to three consecutive valleys; the maximum distance between the hills and the valleys in the lateral direction Y is less than 3 mm, or more precisely less than 2 mm, or more precisely less than 1 mm, or comprised between 0.001 mm and 1 mm, more particularly between 0.001 mm and 0.5 mm, more particularly between 0.001 mm and 0.1 mm.

(129) The 3 consecutive hills or valleys are typically less than the distance corresponding to 15 steps P of protruding elements, preferably less than a distance of 25 mm.

(130) It is advantageous to obtain “straight” edges B, as this eliminates the need for a subsequent edge straightening step, for example a cutting step, as such straight edges are perceived by the user as a sign of product quality.

(131) Furthermore, the equipment and the process used make it possible to obtain such straight edges without the need for extra thicknesses at the edge of the tape, as such extra thicknesses are of no functional interest.

(132) As can be understood from the above description, the straight edges are obtained by injecting the molding material through the material distribution means 106. Subsequent demolding and forming steps retain these straight edges as described above, as long as these steps do not result in the application of forces to the edges of the base 34A of the anti-slip strip 34. The anti-slip strip 34 thus obtained at the end of these various steps therefore has a straight edge as defined above.

(133) For measurements of the coefficient of static friction, residual deformation and elongation at break, the measurement specimens are prepared in a similar manner and according to the method described below.

(134) The laminated assembly is conditioned in a normal atmosphere, as defined in ASTM D5170, at a temperature of 23° C.±2° C. and a relative humidity of 50%±5% for 24 hours.

(135) The coefficient of static friction is measured, in accordance with ASTM D1894, by moving a 200 g (gram) pad with an area of 63 mm×63 mm at a speed of 150 mm/min (millimeters per minute) over the surface of the anti-slip strip.

(136) In the first part of the test, a specimen of the laminated assembly was attached to the friction table of the test system in an absolutely flat position using adhesive tape. The types of tape that may be used to adhere the material specimens to the friction table are well known to people with ordinary skills in the art and therefore will not be described in more detail in the present document.

(137) In another part of the test, the front ear made of a Spunbond nonwoven (60 gsm PP (gram per square centimeter)) of the brand ULTRATEX D 1A 60× available from the firm “TEXBOND nonwovens” is positioned on the lower face of the pad facing the upper face of the specimen of the laminated assembly, with the calendered face of the Spunbond facing the upper face of the specimen of the laminated assembly. The pad is moved in translation on the specimen to be tested over at least a length of 15 mm enabling the value of the coefficient of static friction to be obtained.

(138) For the measurement of the static coefficient of friction at 15% elongation, the specimen of the laminated assembly 30 is held at 15% elongation of the anti-slip strip 34 by double-sided adhesives. The measuring method is the same as for the measurement of the static coefficient of friction at rest.

(139) For a specimen of a laminated assembly without a non-slip strip, for example a laminated assembly marketed under the name “High Stretch Surefit 100” with product number FM27R0140N010-AS02N, available from the firm “APLIX”, the coefficient of static friction is 0.37 in the direction MD and 0.42 in the direction CD at rest.

(140) For a laminated assembly comprising a High Stretch Surefit 100 support layer and an anti-slip strip obtained by means of the molding strip 102 of FIG. 9, the coefficient of static friction is 0.53 in the direction MD and 0.88 in the direction CD at rest and 0.73 in the direction MD and 0.99 in the direction CD when the specimen is stretched by 15% in the direction CD.

(141) For a laminated assembly comprising a High Stretch Surefit 100 support layer and an anti-slip strip obtained by means of the molding strip 102 of FIG. 13, the coefficient of static friction is 0.71 in the direction MD and 1.06 in the direction CD at rest and 0.57 in the direction MD and 1.07 in the direction CD when the specimen is stretched by 15% in the direction CD.

(142) For a laminated assembly comprising a High Stretch Surefit 100 support layer and an anti-slip strip obtained by means of the molding strip 102 of FIG. 15, the coefficient of static friction is 0.54 in the direction MD and 0.72 in the direction CD at rest and 0.79 in the direction MD and 0.84 in the direction CD when the specimen is stretched by 15% in the direction CD.

(143) For measurements of residual deformation and elongation at break, the measuring equipment is a dynamometer according to EN 10002, for example Synergy 200H, 1 column available from MTS Systems Corp. in conjunction with TESTWORKS 4.04B user software.

(144) A specimen 52 is cut with a cutter or scissors to the desired shape, see FIG. 25. The specimen 52 has the general shape of an isosceles trapezium.

(145) The anti-slip strip 34 has a length and a width. When the length of the anti-slip strip is parallel to the direction MD, the specimen 52 has a dimension of 80 mm in the direction CD. The small and large base of the isosceles trapezium are parallel to the direction MD and measure 50 mm and 84 mm respectively, as shown in FIG. 25.

(146) Each edge of the specimen 52 is reinforced with a reinforcement attached to the specimen with double-sided adhesive. Each reinforced edge of the specimen 52 is then placed in a jaw 202, 204 of the dynamometer 200 see FIG. 26). Before testing, the distance between the two jaws 202, 204 is 40 mm.

(147) Elongation at break tests are carried out at a constant speed of movement of the jaws 202, 204 relative to each other. Generally, one jaw is fixed, here the lower jaw 204, and the other jaw is movable, here the upper jaw 202. To carry out the elongation at break test, the movable jaw is moved at a constant speed of 508 mm/min until the break is detected.

(148) The elongation at break tests give the elongation at break at 10 N (newtons) expressed as a percentage of the initial size of the specimen 52 or in mm, the elongation at break expressed as a percentage of the initial size of the specimen 52 or in mm and the force at break expressed in N.

(149) Elongation at break test curves are shown in FIG. 27. On the graph in FIG. 27, the x-axis represents the elongation expressed in percent of the original size of specimen 52 and the y-axis represents the force expressed in N. Curve 1 represents the elongation at break test for a laminated assembly including an anti-slip strip and Curve 2 represents the elongation at break test of the support layer of the laminated assembly of Curve 1, i.e. a laminated assembly without an anti-slip strip. It can be seen that the elongation at break is substantially similar for Curves 1 and 2. On the other hand, the force required to reach the rupture of the specimen 52 is greater when the support layer includes an anti-slip strip. For any elongation prior to the maximum force, the force obtained for a laminated assembly including an anti-slip strip is greater than the force obtained for a laminated assembly without an anti-slip strip.

(150) Residual deformation tests are carried out with the same type of specimen as the specimens 52 of the elongation at break tests and on the same equipment.

(151) The moving jaw has a constant speed of 508 mm/min, the initial jaw distance is 40 mm and the specimen is stretched until a force of 10 N is reached. Once the force of 10 N is reached, the movement of the movable jaw is stopped and the gap is maintained for 30 seconds. The jaw is then moved at constant speed to its starting position and the specimen 52 is held in this position for 60 seconds.

(152) The result is a curve giving the stretching force expressed in N as a function of the elongation expressed in % of the initial specimen size. This curve has a hysteresis which allows the residual or SET deformation at the end of a cycle to be determined as follows: SET=point of intersection with the x-axis of the curve measured during the movement of the movable jaw when the movable jaw returns to its starting position, i.e. a jaw spacing of 40 mm.

(153) Although the present disclosure has been described with reference to a specific example embodiment, it is obvious that various modifications and changes may be made to these examples without going beyond the general scope of the invention as defined by the claims. Furthermore, individual features of the different embodiments referred to may be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than restrictive sense. For example, the anti-slip strip may have a direction MD which is not parallel to the direction MD of the support layer. As an alternative embodiment of embodiments of FIGS. 2A to 8F, 20 to 25 and 28, it is possible to have studs and/or pins and/or stems surmounted by heads according to FIGS. 20 to 23 and/or stems surmounted by heads according to FIG. 28.