MOLDING BELTS WITH WRAPPED STRUCTURING LAYERS

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/708,270, filed October 17, 2024, the substance of which is incorporated herein by reference.

FIELD

The present disclosure relates generally to molding belts and more specifically to molding belts comprising a structuring layer wrapped around at least a portion of a support layer thereof.

BACKGROUND

The discussion of shortcomings and needs existing in the field prior to the present disclosure is in no way an admission that such shortcomings and needs were recognized by those skilled in the art prior to the present disclosure.

The tissue industry is a highly competitive, highly technical industry. It includes a number of paper making processes ranging from low bulk conventional wet press processes to high bulk through air dried (TAD) processes. The papermaking transformations that primarily drive product performance include headbox layering, wet transfer from a forming wire to a molding or structuring template, creping the sheet from a Yankee dryer, and embossing.

Papermaking belts are continuous loops typically formed by taking a strip of material (either a support layer and/or a structuring layer), circling it to bring the ends together, and then joining the ends to form a continuous loop. This process creates one significant joint where the two ends of the article meet perpendicular to the machine direction and going from edge to edge in the cross direction. An alternative method for making belt is using strips of material that are narrower than the width of the finished belt and looping or winding them in a continuous fashion to create a full width belt. This requires joining the edges in the machine direction, cross direction, or in any direction in which the strips of material are wound. Winding creates more joints or seams that need to be managed for quality and runnability.

When two different articles/layers/planes meet an unwanted potential exists for discontinuities such as different sizes in gaps between the two materials, different thicknesses, and differences in the filled pattern areas. Different thicknesses may arise, for example, as an additive thickness if the two articles overlap at the junction, or due to differences associated with article variability in abutting, gap, or overlapping junctions. Differences in the filled pattern areas may arise, for example, if the articles do not exactly mirror or register and align. Discontinuities in openings, closings, thickness, strength, air permeability etc. may translate to discontinuities in the papermaking process that may lead to speed, drying, belt hygiene, creping issues as well as imperfections in the finished sheet. For example, the paper machine will need to slow down to mitigate the impact of “speed bumps” as less speed means less force and more ability for the system to flex and to adsorb the discontinuity of, for example, a dry or wet spot caused by the belt discontinuity or to be able to crepe a heavily patterned area. In a worst case, the areas of discontinuity may create sheet breaks that neither speed nor increasing material or strength may overcome and the belt simply cannot be run continuously.

The discontinuities may also lead to poor absorbency, softness, strength, surface volume, pattern visual and thickness for the consumer in the final paper product. Such issues may impact the ability to convert the substrate into a finished saleable form, with wet spots, caliper changes, strength variability leading to substrate web breaks on a converting line. Thus, discontinuities may disproportionately impact the line when running at higher commercial line speeds. All of these issues may impact the compressibility of a wound roll or stacked sheets, which may impede reliably winding or stacking, packaging, or palletizing the finished product form.

A complication exists in that papermaking belts must balance the need for durability with the need for high air permeability to form fibers and dry the sheet. Hence, papermaking belts, including structuring and supporting layers, are typically designed to be as durable as possible while including as little material as possible. One significant failure mode is holes and tears in the belt, which under the high speeds, temperatures, strains, and loads of papermaking may propagate to a point where the belt is not runnable either because it has lost structural integrity, or it is leaving holes, tears or non-patterned areas in the finished product sheet or causing sheet breaks because of the large discontinuity of the tear or hole. Uniform structuring and support layer materials rely solely on the integrity of the material properties to resist and contain a hole or tear.

A need, therefore, exists for paper making belts that are durable, allow for adequate air flow, and that reduce the issues correlated with discontinuities in structuring layers.

SUMMARY

Various embodiments solve the above-mentioned problems and provide methods and devices useful for paper making belts that are durable, allow for adequate and potentially improved air flow, and that surprisingly reduce the issues correlated with discontinuities in structuring layers by providing a particular type of discontinuity, a gap seam, between non-termini portions of strips wrapped around a support layer to form a structuring layer.

These and other features, aspects, and advantages of various embodiments will become better understood with reference to the following description, figures, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of this disclosure may be better understood with reference to the following figures, which illustrate examples according to various embodiments.

FIG. 1A is a schematic perspective view of a method for wrapping a support layer with a structuring layer.

FIG. 1B is a schematic top view illustration showing a convention for measuring angles between an axis and either the machine direction MD or the cross direction CD.

FIG. 2A is a schematic perspective view of a strip having straight sides at its non-termini portions.

FIG. 2B is a schematic perspective view of a strip having wavy sides at its non-termini portions.

FIG. 2C is a schematic perspective view of a strip having curved sides at its non-termini portions.

FIG. 2D is a schematic perspective view of strip comprising a removable carrier layer and a plurality of strip portions.

FIG. 3A is a schematic perspective view illustrating a termini seam, more specifically an abutting seam between a first termini portion and a second termini portion.

FIG. 3B is a schematic perspective view illustrating a termini seam, more specifically a gap seam between a first termini portion and a second termini portion.

FIG. 3C is a schematic perspective view illustrating a termini seam, more specifically an overlapping seam between a first termini portion and a second termini portion.

FIG. 3D is a schematic perspective view illustrating a termini seam, more specifically a z-interlocking overlap seam between a first termini portion and a second termini portion.

FIG. 3E is a schematic perspective view illustrating a termini seam, more specifically an x-y-interlocking overlap seam between a first termini portion and a second termini portion in a disjoined configuration.

FIG. 3F is a schematic top view illustrating the termini seam from FIG. 3E, more specifically an x-y-interlocking overlap seam between a first termini portion and a second termini portion in a joined configuration.

FIG. 4A is a schematic perspective view of a strip that may be utilized to form a structuring layer having a surface texture comprising a plurality of protrusion.

FIG. 4B is a schematic perspective view of a strip that may be utilized to form a structuring layer having a surface texture comprising a plurality of apertures.

FIG. 4C is a schematic perspective view of a strip that may be utilized to form a structuring layer having a surface texture comprising a plurality of indentations.

FIG. 4D is a schematic perspective view of a strip that may be utilized to form a structuring layer having a surface texture comprising a plurality of protrusions, a plurality of apertures, and a plurality of indentations.

FIG. 5A is a schematic perspective view of a web material structuring belt comprising a support layer and a structuring layer, the structuring layer comprising one or more strips externally wrapped in a machine direction MD about a support layer and disposed in a facing relationship with the support layer.

FIG. 5B is a schematic perspective view of a portion of the web material structuring belt of FIG. 5A.

FIG. 6A is a schematic perspective view of a web material structuring belt comprising a support layer and a structuring layer, the structuring layer comprising one or more strips externally and spirally wrapped in a machine direction MD about a support layer and disposed in a facing relationship with the support layer.

FIG. 6B is a schematic perspective view of a portion of the web material structuring belt of FIG. 6A.

FIG. 7A is a schematic perspective view of a web material structuring belt comprising a structuring layer, the structuring layer comprising one or more strips internally wrapped in a cross direction CD about a support layer and disposed in a facing relationship with the support layer.

FIG. 7B is a schematic perspective view of a portion of the web material structuring belt of FIG. 7A.

FIG. 8A is a schematic perspective view of a web material structuring belt comprising a support layer a structuring layer, the structuring layer comprising one or more strips internally and spirally wrapped in a cross direction CD about a support layer and disposed in a facing relationship with the support layer.

FIG. 8B is a schematic perspective view of a portion of the web material structuring belt of FIG. 8A.

FIG. 9A is a schematic perspective view of a web material structuring belt comprising a support layer, the structuring layer comprising one or more strips externally wrapped in a cross direction CD about a support layer and disposed in a facing relationship with the support layer.

FIG. 9B is a schematic perspective view of a portion of the web material structuring belt of FIG. 9A after external flap folds are cut away to expose cut ends of the structuring layers.

FIG. 10A is a schematic perspective view of a web material structuring belt comprising a support layer, the structuring layer comprising one or more strips externally and spirally wrapped in a cross direction CD about a support layer and disposed in a facing relationship with the support layer.

FIG. 10B is a schematic perspective view of a portion of the web material structuring belt of FIG. 10A after external flap folds are cut away to expose cut ends of the structuring layers.

FIG. 11 is a schematic perspective view of a web material structuring belt comprising a support layer and a structuring layer comprising one or more strips disposed in a facing relationship with the support layer.

FIG. 12 is a schematic perspective view of a web material structuring belt comprising a support layer and a structuring layer, comprising one or more strips disposed in a facing relationship with the support layer.

FIG. 13 is a schematic perspective view of a web material structuring belt comprising a support layer and a structuring layer, comprising one or more strips disposed in a facing relationship with the support layer.

FIG. 14 is a schematic top view of a web material structuring belt comprising a support layer and a structuring layer, comprising one or more strips disposed in a facing relationship with the support layer, showing an abutting seam between non-termini portions of at least one structuring layer.

FIG. 15 is a schematic top view of a web material structuring belt comprising a support layer and a structuring layer, comprising one or more strips disposed in a facing relationship with the support layer, showing an x-y interlocking seam between non-termini portions of at least one structuring layer.

FIG. 16 is a schematic top view of a web material structuring belt comprising a support layer and a structuring layer, comprising one or more strips disposed in a facing relationship with the support layer, showing an overlap seam between non-termini portions of at least one structuring layer.

It should be understood that the various embodiments are not limited to the examples illustrated in the figures.

DETAILED DESCRIPTION

Introduction and Definitions

This disclosure is written to describe the invention to a person having ordinary skill in the art, who will understand that this disclosure is not limited to the specific examples or embodiments described. The examples and embodiments are single instances of the invention which will make a much larger scope apparent to the person having ordinary skill in the art. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by the person having ordinary skill in the art. It is also to be understood that the terminology used herein is for the purpose of describing examples and embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

All the features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to the person having ordinary skill in the art and are to be included within the spirit and purview of this application. Many variations and modifications may be made to the embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure. For example, unless otherwise indicated, the present disclosure is not limited to particular materials, manufacturing processes, or the like, as such may vary. It is also to be understood that the terminology used herein is for purposes of describing particular embodiments only and is not intended to be limiting. It is also possible in the present disclosure that steps may be executed in different sequence where this is logically possible.

All numeric values are herein assumed to be modified by the term “about,” whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (for example, having the same function or result). In many instances, the term “about” may include numbers that are rounded to the nearest significant figure.

In everyday usage, indefinite articles (like “a” or “an”) precede countable nouns and noncountable nouns almost never take indefinite articles. It must be noted, therefore, that, as used in this specification and in the claims that follow, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a support” includes a plurality of supports. Particularly when a single countable noun is listed as an element in a claim, this specification will generally use a phrase such as “a single.” For example, “a single support.”

Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit (unless the context clearly dictates otherwise), between the upper and lower limit of that range, and any other stated or intervening value in that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings unless a contrary intention is apparent.

“Disposed on” refers to a positional state indicating that one object or material is arranged in a position adjacent to the position of another object or material. The term does not require or exclude the presence of intervening objects, materials, or layers.

“Align” or “aligned” or “aligning” means to place or to arrange in a straight line or along an axis. Aligning edges of substrates or layers, therefore, means arranging the substrates so that the edges in question extend along approximately the same line or along approximately parallel lines. It is to be appreciated that aligning edges of substrates may be accomplished in a variety of ways, including placing the substrates one on top of the other or side by side.

“Facing relationship” refers to a relative positioning of materials, such as substrates, in which a surface of one material is oriented toward a surface of another material. For example, when two layers are stacked on top of each other, they are in a facing relationship. The term does not require or exclude the presence of intervening objects, materials, or layers. Any of the structuring layers described herein may be placed into a facing relationship with other structuring layers and/or with a support layer.

“Machine direction” (MD) refers to the direction of material flow through a process. In addition, relative placement and movement of material may be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.

“Cross direction” (CD) refers to a direction that is generally perpendicular to the machine direction.

“Major axis” of an elongated strip refers to the longest straight line that may be drawn within the strip, extending from one end of the strip to the other, and passing through its center or midpoint. The major axis may define the primary direction of elongation and represents the strip's greatest dimension in terms of length. In many cases, the major axis may be used as a reference for measuring and describing the strip's size and orientation.

“Minor axis” of an elongated strip refers to the shortest straight line that may be drawn within the strip, perpendicular to its major axis, and passing through the strip’s center or midpoint. The minor axis may represents the strip's smallest dimension in terms of width or thickness.

“Termini” refers to the two opposite ends or extremities of a long, narrow object, material, or structure. These are the specific points or sections located at the furthest points from each other along the length of the structure. In other words, it may refer to portions of an elongated strip located at the furthest points from each other along the length of the elongated strip. As an example, a termini portion of a strip may be an end, a side, or an edge of the strip lying at one of two furthest extremities along a major axis of the strip or along an axis that is parallel to the major axis.

“Non-termini” refers to the central or intermediate section of a long, narrow object, material, or structure that is not located at either end or extremity. In other words, it may refer to portions of an elongated strip that lies between the two ends or termini. This portion may vary in length and width, but it is distinct from the ends or termini. As an example, a non-termini portion of a strip may be an end, a side, or an edge of the strip lying at one of two furthest extremities along a minor axis of the strip or along an axis that is parallel to the minor axis.

“Seam” refers to a perceptible or conceptual boundary, interface, or transition zone between two materials, surfaces, or edges, characterized by their close proximity, adjacency, and/or alignment.

“Non-termini seam” in the context of an elongated strip refers to a perceptible or conceptual boundary or interface that exists along the length of the strip but that does not occur at either end of the strip. This seam may exist, for example, between adjacent non-termini portions of one or more strips wound about a support layer. In essence, a non-termini seam is a seam that runs along the body of the elongated strip.

“Termini seam” in the context of an elongated strip refers to a perceptible or conceptual boundary or interface that occurs specifically at one or both ends of the strip. This seam is characterized by its presence at the strip’s endpoints. In other words, a termini seam is a seam that is located at the extremities of the elongated strip, where the strip physically ends or terminates.

“Abutting seam” may refer to a type of termini seam or to a type of non-termini seam. In the context of a termini seam, “abutting seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first termini portion and a second termini portion, in which the first termini portion contacts but does not overlap or interlock with the second termini portion. In the context of a non-termini seam, “abutting seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first non-termini portion and a second non-termini portion, in which the first non-termini portion contacts but does not overlap or interlock with the second non-termini portion. In either context, the first non-termini portion and the second non-termini portion may be components of the same or different elongated strip or structuring layer, for example.

“Gap seam” may refer to a type of termini seam or to a type of non-termini seam. In the context of a termini seam, “gap seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first termini portion and a second termini portion, characterized by a deliberate gap or space therebetween. Unlike an abutting seam, where the ends of the strip come into direct contact, a gap seam leaves a space or opening between the ends of the strip. In the context of a non-termini seam, “gap seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first non-termini portion and a second non-termini portion, characterized by a deliberate gap or space therebetween. Unlike an abutting seam, where the sides of a strip or a pair of adjacent strips come into direct contact, a gap seam leaves a space or opening between the adjacent non-termini sides. In either context, the first non-termini portion and the second non-termini portion may be components of the same or different elongated strip or structuring layer, for example.

“Overlapping seam” may refer to a type of termini seam or to a type of non-termini seam. In the context of a termini seam, “overlapping seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first termini portion and a second termini portion, in which the first termini portion extends over the second termini portion to cover it partly or completely. In the context of a non-termini seam, “overlapping seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first non-termini portion and a second non-termini portion, in which the first termini portion extends over the second termini portion to cover it partly or completely. In either context, the first non-termini portion and the second non-termini portion may be components of the same or different elongated strip or structuring layer, for example.

“x-y interlocking overlap seam” may refer to a type of termini seam or to a type of non-termini seam. In the context of a termini seam, “x-y interlocking overlap seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first termini portion and a second termini portion, in which the first termini portion interlocks with the second termini portion to resist separation in an x-direction, along the minor axis, and in a y-direction long the major axis. In the context of a non-termini seam, “x-y interlocking overlap seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first non-termini portion and a second non-termini portion, in which the first non-termini portion interlocks with the second non-termini portion to resist separation in an x-direction, along the minor axis, and in a y-direction long the major axis. In either context, the first non-termini portion and the second non-termini portion may be components of the same or different elongated strip or structuring layer, for example.

“z-interlocking overlap seam” may refer to a type of termini seam or to a type of non-termini seam. In the context of a termini seam, “z-interlocking overlap seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first termini portion and a second termini portion, in which in which the first termini portion interlocks or at least overlaps with the second termini portion to resist separation in a z-direction that is orthogonal to the major and minor axis. In the context of a non-termini seam, “z-interlocking overlap seam” refers to a perceptible or conceptual boundary, interface, or transition zone between a first non-termini portion and a second non-termini portion, in which the first non-termini portion interlocks or at least overlaps with the second non-termini portion to resist separation in a z-direction that is orthogonal to the major and minor axis.

“Internally wrapped” refers to a method of wrapping or winding a strip of material in such a way that it passes through the central space or core of another object, such as a support layer in the form of a continuous or endless loop. The term may also describe the state of a strip after wrapped about a support layer according to such a method.

“Externally wrapped” refers to a method of wrapping or winding a strip of material in such a way that it does not pass through the central space or core of another object, such as a support layer in the form of a continuous or endless loop. The term may also describe the state of a strip after wrapped about a support layer according to such a method.

“Wrapped in a direction” such as “wrapped in a machine direction MD” or “wrapped in a cross direction CD” refers to the act of winding or encircling an object with a material, such as a strip of fabric, tape, or any flexible material, while following a specific path or orientation. This path or orientation may be linear, curved, diagonal, or any other specified course, depending on the intended purpose or design. The phrase “wrapping in a direction” highlights the deliberate and controlled manner in which an object is enveloped or covered by a material, taking into consideration the desired path or orientation of the wrapping process. The term may also describe the state of a strip after wrapped about a support layer according to such a method.

“Spirally wrapped” refers to a method of wrapping or winding a material, such as a strip of fabric, tape, wire, or any flexible substance, around an object in a spiral or helical fashion. In this wrapping technique, the material is wound around the object’s surface in a continuous, repetitive spiral pattern, creating layers of overlapping or closely spaced turns. “Spirally wrapped” emphasizes the helical or spiral nature of the wrapping pattern, distinguishing it from other wrapping techniques that may involve linear or more complex winding patterns. The term may also describe the state of a strip after wrapped about a support layer according to such a method.

FIG. 1A is a schematic perspective view of a method 10 for wrapping a support layer 200 with a structuring layer 300. The method 10 may comprise disposing the support layer 200 on a plurality of rollers 14 supported by a mandrel stand 12. The rollers 14 that support the support layer 200 may extend from the mandrel stand 12 in a cross direction CD that is substantially orthogonal to a machine direction MD in which the support layer will ultimately be used as a component of a web material structuring belt. A second set of removable mandrel stands 12 could be disposed opposite the first set to eliminate cantilevering of the rollers 14. The second set would be removable to allow belts to be put on and taken off the rollers. The structuring layer 300 may comprise a structuring layer material 301, in the form of a strip 400, which may optionally coiled into a roll 302. The strip 400 may be disposed on the support layer 200 in a facing relationship therewith. The strip 400 may comprise a major axis 440 and may be disposed on the support layer such that the major axis 440 is at a first angle 441 relative to the machine direction MD and at a second angle 442 relative to the cross direction CD.

FIG. 1B is a schematic top view illustration showing a convention for measuring angles between an axis and either the machine direction MD or the cross direction CD. It is to be appreciated that the machine direction MD may extend in two directions as shown. Similarly, it is to be appreciated that the cross direction CD may extend in two direction as shown. The machine direction MD and the cross direction CD may intersect and may be orthogonal relative to each other. To measure the angle at which an axis 440a, 440b is positioned relative to the machine direction MD, start on the line defining the machine direction MD and rotate toward the axis in either a clockwise or a counterclockwise direction about the intersection of the machine direction and the cross direction to reach the axis. Counterclockwise rotation results in a negative angle. Clockwise rotation results in a positive angle. It is to be appreciated that the axis 440a, 440b may be at any angle relative to the cross direction CD, but that once the angle reaches 90 degrees or -90 degrees, it is more practical to measure the angle relative to the machine direction MD. Similarly, the axis 440a, 440b may be at any angle relative to the machine direction MD, but that once the angle reaches 90 degrees or -90 degrees, it is more practical to measure the angle relative to the cross direction CD. Thus, practically speaking the angle may always be expressed in a range of from 0 to 90 degrees or from 0 to -90 degrees. For example, angle 441a may be from 0 (440a is aligned with the machine direction MD) to -90 (440a is aligned with the cross direction CD). Similarly, angle 441b can be from 0 (440b is aligned with the machine direction MD) to 90 (440b is aligned with the cross direction CD). Likewise, angle 442a can be from 0 (440a is aligned with the cross direction CD) to 90 (440a is aligned with the machine direction MD). Finally, angle 441b can be from 0 (440b is aligned with the cross direction CD) to -90 (440b is aligned with the machine direction MD).

Referring again to FIG. 1, it is to be appreciated that the first angle 441 relative to the machine direction MD may be from about -90 degrees to about 90 degrees, or from greater than -90 to less than 90 degrees, or from greater than about -90 to less than about 90 degrees, or from about -85 degrees to about 85 degrees, or from about -80 degrees to about 80 degrees, or from about -75 degrees to about 75 degrees, or from about -70 degrees to about 70 degrees, or from about -65 degrees to about 65 degrees, or from about -60 degrees to about 60 degrees, or from about -55 degrees to about 55 degrees, or from about -50 degrees to about 50 degrees, or from about -45 degrees to about 45 degrees, or from about -40 degrees to about 40 degrees, or from about -35 degrees to about 35 degrees, or from about -30 degrees to about 30 degrees, or from about -25 degrees to about 25 degrees, or from about -20 degrees to about 20 degrees, or from about -15 degrees to about 15 degrees, or from about -10 degrees to about 10 degrees, or from about -5 degrees to about 5 degrees, or about 0 degrees.

It is to be appreciated that since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. The second angle 442 relative to the cross direction CD may be from about -90 degrees to about 90 degrees, or from greater than -90 to less than 90 degrees, or from greater than about -90 to less than about 90 degrees, or from about -85 degrees to about 85 degrees, or from about -80 degrees to about 80 degrees, or from about -75 degrees to about 75 degrees, or from about -70 degrees to about 70 degrees, or from about -65 degrees to about 65 degrees, or from about -60 degrees to about 60 degrees, or from about -55 degrees to about 55 degrees, or from about -50 degrees to about 50 degrees, or from about -45 degrees to about 45 degrees, or from about -40 degrees to about 40 degrees, or from about -35 degrees to about 35 degrees, or from about -30 degrees to about 30 degrees, or from about -25 degrees to about 25 degrees, or from about -20 degrees to about 20 degrees, or from about -15 degrees to about 15 degrees, or from about -10 degrees to about 10 degrees, or from about -5 degrees to about 5 degrees, or about 0 degrees.

For all embodiments described herein, it is to be appreciated that the first angle 441 and the second angle 442 may be the same or different. It is also to be appreciated, for all embodiments described herein that the first angle 441 and/or the second angle 442 may vary for adjacent strips 400 and may even vary for a single strip 400 when the single strip 400 is repeatedly wrapped around the support layer 200 the angle 441 and/or the angle 442 may vary for adjacent portions of the same strip 400.

FIG. 2A, FIG. 2B, and FIG. 2C cooperate to illustrate various strips 400 having non-termini portions 420 and termini portions 430. Each strip 400 may comprise a major axis 440 extending between termini portions 430 of the strip 400. Each strip 400 may also comprise and a minor axis 450 extending between non-termini portions 420 of the strip 400. For example, FIG. 2A is a schematic perspective view of a strip 400 having straight sides 421 at its non-termini portions 420, which may include a first non-termini portion 420a and a second non-termini portion 420b.

The structuring layer strip may have a total length L, extending along the major axis 440 of from about 6 in (0.1524 m) to unlimited length, or about 12 in (0.3048 m) to about 10000 ft (3048 m), or about 24 in (0.6096 m) to about 10000 in (254 m). The total length L may also be from about 0.1 m to about 5000 m, or about 1 m to about 4500 m, or about 5 m to about 4000 m, or about 10 m to about 3500 m, or about 100 m to about 3000 m, or about 500 m to about 2500 m, or about 1000 m to about 2000 m, or about 1500 m.

The structuring layer strip may have a width W, extending perpendicularly to the major axis 440 of from about 1/32 in (0.0008 m) to about 100 ft (30.48 m), or about 1/32 in (0.0008 m) to about 50 ft (15.24 m), or about 1/16 in (0.0016 m) to about 25 ft (7.62 m), or about 1/8 in (0.0032 m) to about 12 ft (3.6576 m). The width W may also be from about 0.01 cm to about 5000 cm, or about 0.1 cm to about 4500 cm, or about 1 cm to about 4000 cm, or about 5 cm to about 3500 cm, or about 10 cm to about 3000 cm, or about 100 cm to about 2500 cm, or about 500 cm to about 2000 cm, or about 1000 cm to about 1500 cm.

FIG. 2B is a schematic perspective view of a strip 400 having patterned sides 422, specifically sides having a repeating wave-like pattern, at its non-termini portions 420, which may include a first non-termini portion 420a and a second non-termini portion 420b. FIG. 2C is a schematic perspective view of a strip 400 having curved sides 423 at its non-termini portions 420, which may include a first non-termini portion 420a and a second non-termini portion 420b. The illustrated sides 421, 422, 423 are examples and it is to be appreciated that any pattern may be employed, including but not limited to zig-zags and random patterns. It is also to be appreciated that although the sides 421, 422, 423 of the illustrated strips are approximately parallel, this need not be the case. Additionally, any combination of patterns may be employed, for example, on side of a strip 400 may be straight and another side of that same strip 400 may be curved, wavy, or zig-zagged.

According to various embodiments, it is possible to create a structuring layer material 3 mm wide and approximately 23,000 kilometers long. The structuring layer may have straight edges or curved or any variety of shape. The layer may have holes of any geometry. The structuring layer does not need to be continuous – if it is unable to hold itself together in a single layer a topical layer with light temporary adhesive may be used to maintain the integrity of the layer through treatment of bonding with the support layer. Optionally an associating layer may be used to carry the discontinuous structuring pattern, as described in US Pat. Application Serial No. US 2023/0138090 and US Pat. Application Serial No. US 2023/0137439, which are hereby incorporated by reference in their entireties. For example, according to various embodiments, it is possible to place an endless support layer approximately 5.2 meters wide and 21.3meters circumference with optionally applied associating material, bonding layer (as described in in US Pat. Application Serial No. US 2023/0139935, which is incorporated by reference in its entirety) or modifying material (as described in US Pat. Application Serial No. US 2023/0140783, which is incorporated by reference in its entirety) onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate an orthogonal or spiral wrap in the machine direction or cross direction by positioning the structuring layer and the support layer in contact with one another. According to various embodiments, it is possible to continue the wind across to cover the support layer so that the structuring layer leaves a 2 mm gap seam between the non-termini edges of each wrap. The termini seams may be abut, gap, or overlap. For example, according to various embodiments, it is possible to treat the layers to bond, as for example in US20230138090. The structuring layer pattern and the non-termini gap seam may become an integrated macro pattern.

According to various embodiments, it is possible to create a structuring layer material with non-thermoplastic, thermoset polymer, UV light curable polymer, silicone rubber and/or non-silicone vulcanized rubber film or apertured film and/or porous film and/or laser-abraded film and/or laser-etched film and/or perforated film narrower than the width of the support layer and where the layer has a curvature such that the second non-termini edge is longer in length than the first non-termini edge. Alternatively, according to various embodiments, it is possible to provide a structuring layer of woven material, wire mesh or extruded plastic netting narrower than the width of the support layer where the layer has a curvature such that the second non-termini edge is longer in length than the first non-termini edge. It is to be appreciated that these material options for the structuring layer apply to all of the examples and embodiments described herein. According to various embodiments, it is possible to place an endless support layer onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. Optionally, according to various embodiments, it is possible to apply an associating material, bonding layer or modifying material to the support layer. According to various embodiments, it is possible to initiate the spiral wrap by positioning the structuring layer and the support layer in contact with one another so that a non-termini edge is facing the direction the spiral wrap is intended to progress across the support layer. According to various embodiments, it is possible to continue to contact the structuring layer with the bonding layer leaving a 2.5mm gap between non-termini edges of successive wraps. Finally, according to various embodiments, it is possible to treat the layers to bond them.

FIG. 2D is a schematic perspective view of strip 400 comprising a removable carrier layer 460 and a plurality of strip portions 462. Such a strip 400 may be disposed on a support layer so that the strip portions 462 may be in a facing relationship with the support layer and then the removable carrier layer 460 may be removed, leaving the strip portions 462 on the support layer. Thus, each of the strip portions 462 may have termini ends 430 and non-termini ends 420. The strip 400 may have a major axis 440 and a minor axis 450, and each strip portion may have a major axis 440a and a minor axis 450a.

FIG. 3A, FIG. 3B, FIG. 3C, FIG. 3D, FIG. 3E, and FIG. 3F cooperate to illustrate various types of seams. FIG. 3A is a schematic perspective view illustrating a termini seam 500, more specifically an abutting seam 501 between a first termini portion 430a and a second termini portion 430b. FIG. 3B is a schematic perspective view illustrating a termini seam 500, more specifically a gap seam 502 between a first termini portion 430a and a second termini portion 430b. FIG. 3C is a schematic perspective view illustrating a termini seam 500, more specifically an overlapping seam 503 between a first termini portion 430a and a second termini portion 430b. FIG. 3D is a schematic perspective view illustrating a termini seam 500, more specifically a z-interlocking overlap seam 504 between a first termini portion 430a and a second termini portion 430b. FIG. 3E is a schematic perspective view illustrating a termini seam 500, more specifically an x-y-interlocking overlap seam 505 between a first termini portion 430a and a second termini portion 430b in a disjoined configuration. FIG. 3F is a schematic top view illustrating the termini seam 500 from FIG. 3E, more specifically an x-y-interlocking overlap seam 505 between a first termini portion 430a and a second termini portion 430b in a joined configuration. The seams 500 are shown as being substantially orthogonal to the major axis 440, but it is to be appreciated that an seams 500 may be at any angle relative to the major axis 440.

FIG. 4A, FIG. 4B, FIG. 4C, and FIG. 4D cooperate to illustrate various surface textures 310 that a strip 400 may comprise. FIG. 4A is a schematic perspective view of a strip 400 that may be utilized to form a structuring layer 300 having a surface texture 310 comprising a plurality of protrusions 312. FIG. 4B is a schematic perspective view of a strip 400 that may be utilized to form a structuring layer 300 having a surface texture 310 comprising a plurality of apertures 314. FIG. 4C is a schematic perspective view of a strip 400 that may be utilized to form a structuring layer 300 having a surface texture 310 comprising a plurality of indentations 316. FIG. 4D is a schematic perspective view of a strip 400 that may be utilized to form a structuring layer 300 having a surface texture 310 comprising a plurality of protrusions 312, a plurality of apertures 314, and a plurality of indentations 316. It is to be appreciated that any combination of such features 310 may be employed. It is also to be appreciated that such surface features 310 are not limited to circular shapes; any shape may be employed. For example, the surface features 310 may have geometric shapes having n-sides, where n is from 3 to 10. Additionally or alternatively, the surface features 310 may have patterned shapes, such as lines, wavy lines, zig-zags, or artistic designs.

FIG. 5A and FIG. 5B cooperate to illustrate a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300. The structuring layer 300 may comprise one or more strips 400 externally wrapped in a machine direction MD about the support layer 200 and disposed in a facing relationship with the support layer 200. FIG. 5A is a schematic perspective view. FIG. 5B is a schematic perspective view of a portion of the web material structuring belt 100 of FIG. 5A.

Each strip 400 may have a major axis 440 that is disposed parallel to, substantially parallel to, aligned with, or substantially aligned with the machine direction MD, such that the angle 441 between the major axis 440 and the machine direction MD may be in a range of from -5 degrees to 5 degrees, or about -5 degrees to about 5 degrees, or about -4 degrees to about 4 degrees, or about -3 degrees to about 3 degrees, or about -2 degrees to about 2 degrees, or about -1 degrees to about 1 degrees, or about 0 degrees, or 0 degrees.

It is to be appreciated that since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. For example, the angle 442 between the major axis 440 of each strip and the cross-direction CD may be 90 degrees, or about 90 degrees, or in a range of from about 85 degrees to about 90 degrees, or about 85 degrees to about 90 degrees, or about 86 degrees to about 90 degrees, or about 87 degrees to about 90 degrees or about 88 to 90 or about 89 to 90. Alternatively, the angle 442 between the major axis 440 of each strip and the cross-direction CD may be -90 degrees, or about -90 degrees, or in a range of from about -85 degrees to about -90 degrees, or about -85 degrees to about -90 degrees, or about -86 degrees to about -90 degrees, or about -88 degrees to about -90 degrees or about -88 to- 90 or about -89 to -90.

As shown, the strips 400 may be separated one from another by a non-termini seam 600. The non-termini seam 600 may be a gap seam 602. It is to be appreciated, and will be illustrated hereinafter, for example, in FIG. 15, FIG. 16, and FIG. 17, that the non-termini seams 600 between each strip 400 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of non-termini seams 600 may be employed. Since a structuring layer 400 externally wrapped in a machine direction MD about a support layer 200 as illustrated in FIG. 5A and FIG. 5B does not repeatedly spiral around the support layer 200, each of the plurality of strips 400 may comprise a termini seam 500. As illustrated, the termini seams 500 are abutting seams 501. It is to be appreciated that the termini seams 500 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of termini seam 500 may be employed. In other words, different strips 400 may employ different types of termini seams 500.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place the endless support layer onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. Optionally, it is possible to apply an associating material, bonding layer or modifying material to the support layer. According to various embodiments, it is possible to initiate the orthogonal wrap by positioning the structuring layer and the support layer in contact with one another so that the first side of the first structuring layer wrap non-termini edges align with the support layer first MD edge. According to various embodiments, it is possible to wrap the length of structuring layer fully around the endless support layer, until the structuring layer passes over the first termini edge. With the structuring layer overlapping itself, it is possible to cut through both layers with a cut 5 degrees from perpendicular with the non-termini edges of the structuring layer material, to create an abut seam on a 5 degree angle. Optionally, the seam may be cut to have a gap, abut, or overlap, or any combination of seam types. Optionally the seam may be cut parallel to the cross direction or up to 45 degrees from parallel to the cross direction of the support layer. According to various embodiments, it is possible to treat the entire first orthogonal wrap of structing material in contact with the support layer to bond the two layers. Next, it is possible to increment a new length of structuring material layer over 1/8” to create a gap seam between the second non-termini edge of the first wrap and the first non-termini edge of the second wrap. According to various embodiments, it is possible to place the termini edge of the second wrap approximately 1 inch further in the machine direction than the first wrap termini seam. Optionally the first and second seams may be in line or up to 10 feet apart. According to various embodiments, it is possible to maintain parallel placement of the second structuring layer wrap with the edge of the support layer and with the first wrap second non-termini edge. When this wrap of structuring layer overlaps with itself, it is possible to cut through both structuring layers with a cut 5 degrees for perpendicular with the non-termini edges of the structuring layer material, to create an structuring layer abut seam on a 5 degree angle. Optionally, the seam may be cut to have a gap, abut, or overlap, or combination of seam types. Optionally the seam may be cut parallel to the cross direction or up to 45 degrees from parallel to the cross direction of the support layer. According to various embodiments, it is possible to treat the second orthogonal wrap of structing material in contact with the support layer to bond the layers. According to various embodiments, it is possible to continue with orthogonal wrap segments offset by 1/8” gap seam and termini abut seams offset by approximately 1 inch in the machine direction from the previous wrap and bonding the structuring and support layers of the wrap until the structuring layer extends past the support layer MD edge on the other side of the endless loop (second MD edge). According to various embodiments, it is possible to trim any excess structuring layer that extends past the support layer. Optionally the structuring and support layer may be treated to bond the layers after all the wraps have been completed by temporarily affixing the orthogonal wrap termini edges across the belt with tape until the bonding process is begun.

FIG. 6A and FIG. 6B cooperate to illustrate a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300. The structuring layer 300 may comprise one or more strips 400 externally and spirally wrapped in a machine direction MD about the support layer 200 and disposed in a facing relationship with the support layer 200. FIG. 6A is a schematic perspective view. FIG. 6B is a schematic perspective view of a portion of the web material structuring belt 100 of FIG. 6A. Each strip 400 may have a major axis 440 that is at an angle 441 relative to the machine direction.

It is to be appreciated that the angle 441 relative to the machine direction MD may be any angle, but that to allow the strip 400 to spiral around the support layer 200 in a machine oriented direction, the angle 441 may be any angle other than 0 degrees, 90 degrees, or -90 degrees. For example, the angle 441 may be from greater than 0 degrees to less than 90 degrees, or greater than about 0 degrees to less than about 90 degrees, or about 3 degrees to about 80 degrees, or about 6 degrees to about 70 degrees, or about 8 degrees to about 60 degrees, or about 10 degrees to about 50 degrees, or about 12 degrees to about 45 degrees, or about 15 degrees to about 35 degrees, or about 18 degrees to about 25 degrees, or about 20 degrees to about 25 degrees, or about 22.5 degrees. Alternatively, the angle 441 may be from less than 0 degrees to greater than -90 degrees, or less than about 0 degrees to greater than about -90 degrees, or about -3 degrees to about -805 degrees, or about -6 degrees to about -70 degrees, or about -8 degrees to about -60 degrees, or about -10 degrees to about -50 degrees, or about -12 degrees to about -45 degrees, or about -15 degrees to about -35 degrees, or about -18 degrees to about -25 degrees, or about -20 degrees to about -25 degrees, or about -22.5 degrees.

It is to be appreciated that since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. The angle 441 may vary for adjacent strips 400 and even in a case where a single strip 400 is repeatedly wrapped around the support layer 200 the angle 441 may vary for adjacent portions of the same strip 400. As shown, the strips 400 may be separated one from another by a non-termini seam 600. The non-termini seam 600 may be a gap seam 602. It is to be appreciated, and will be illustrated hereinafter, for example, in FIG. 15, FIG. 16, and FIG. 17, that the non-termini seams 600 between each strip 400 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of non-termini seams 600 may be employed. Termini portions of a strip 400 or plurality of strips 400 may comprise a termini seam 500. As illustrated, a termini seam 500 may be an abutting seam 501. It is to be appreciated that the termini seams 500 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of termini seam 500 may be employed. In other words, different strips may employ different types of termini seams.

According to various embodiments, it is possible to create a structuring layer material with non-thermoplastic, thermoset polymer, UV light curable polymer, silicone rubber and/or non-silicone vulcanized rubber film or apertured film and/or porous film and/or laser-abraded film and/or laser-etched film and/or perforated film narrower than the width of the support layer. Alternatively provide a structuring layer of woven material, wire mesh or extruded plastic netting narrower than the width of the support layer. The total length may be supplied in one continuous layer or several discrete increments. According to various embodiments, it is possible to place the endless support layer onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. Optionally, it is possible to apply an associating material, bonding layer or modifying material to the support layer. Initiate the spiral wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are rotated +10 degrees from MD. Optionally, the non-termini edges may be parallel (0 degrees) to 45 degrees or +45 degrees from MD . According to various embodiments, it is possible to translate the structuring layer to induce spiral wrap around the support layer up to the first mandrel. Next, it is possible to treat the segment of the structuring layer material in contact with the support layer to bond the layers together. According to various embodiments, it is possible to continue to translate the structuring layer about the support layer to spirally wrap the structuring layer material around the support layer passing over the first mandrel and coming around to the opposing face of the support layer. According to various embodiments, it is possible to treat this length of structing material in contact with the support layer to bond the layers. According to various embodiments, it is possible to continue translating the structuring layer to spirally wrap the support layer around the second mandrel area and up past the plane of the first termini edge of the structuring layer material, allowing the translation to leave a 1/8” gap with between the second non-termini edge of the first wrap and the first non-termini end of the second spiral wrap. If the structuring layer was discrete segments rather than one continuous strip, it is possible to create abut, overlap and/or gap seams on the termini edges to continue translating and spiral winding until the entire support layer surface is covered by structuring layer or gap seam. According to various embodiments, it is possible to treat this successive length of structuring material in contact with the support layer to bond the layers. According to various embodiments, it is possible to continue translating the structuring layer to spirally wrap the support layer, leaving 1/8” gap between the second non-termini edge of the former wrap and the first non-termini end of the latter spiral wrap and treating the layers to bond. According to various embodiments, it is possible to cut away any structuring layer material that extends past the support layer. According to various embodiments, it is possible to return to the initial termini end and first wrap non termini edges of the structuring layer. According to various embodiments, it is possible to fill any area of the surface of the support layer that does not have structuring layer bonded to it by cutting a structuring layer shape that meets with an abut, gap or overlap or combination of any of these types of seem at the first termini edge, a 1/8” gap seam with the first non-termini edge and fills up to the edge of the support layer . According to various embodiments, it is possible to treat this portion of the structuring layer in contact with the support layer to bond the materials together.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place the endless support layer onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. Optionally, it is possible to apply an associating material, bonding layer or modifying material to the support layer. According to various embodiments, it is possible to initiate the first angled wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are rotated +5 degrees from the support layer machine direction. According to various embodiments, it is possible to continue to wrap in a rotated direction the structuring layer material around the support layer passing over one of the support mandrel areas and coming around to the opposing face of the support layer. According to various embodiments, it is possible to continue to wrap in a rotated direction the structuring layer around the second mandrel area and up over the first termini edge of the structuring layer material so that the non-termini edges of the structing layer are aligned. According to various embodiments, it is possible to treat this wrap of structuring material in contact with the support layer to bond the two layers. According to various embodiments, it is possible to increment over 0.5 to 4mm and start another angled wrap. This wrap may be rotated on the same angle as the initial or rotated on a different angle between +0.5 and +45 degrees or -0.5 and -45 degrees from the machine direction. According to various embodiments, it is possible to continue to wrap and treat to bond until the support layer has been fully covered by structuring layer and gap seam increments. According to various embodiments, it is possible to cut away any structuring layer material that extends past the support layer.

FIG. 7A and FIG. 7B cooperate to illustrate a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300. The structuring layer 300 may comprise one or more strips 400 internally wrapped in a cross direction CD about the support layer 200 and disposed in a facing relationship with the support layer 200. FIG. 7A is a schematic perspective view. FIG. 7B is a schematic perspective view of a portion of the web material structuring belt 100 of FIG. 7A.

Each strip 400 may have a major axis 440 that is disposed perpendicularly or substantially perpendicularly with the machine direction MD, such that an angle 441 between the major axis 440 and the machine direction may be 90 degrees, or about 90 degrees, or in a range of from about 85 degrees to about 90 degrees, or about 86 degrees to about 90 degrees, or about 87 degrees to about 90 degrees or 88 to 90 or 89 to 90. Alternatively, the angle 441 may be -90 degrees, or about -90 degrees, or in a range of from about -85 degrees to about -90 degrees, or about -86 degrees to about -90 degrees, or about -87 degrees to about -90 degrees or -88 to 90 or -89 to 90.

It is to be appreciated that since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. For example, the angle 442 between the major axis 440 of each strip and the cross-direction may be in a range of from -5 degrees to 5 degrees, or about -5 degrees to about 5 degrees, or about -4 degrees to about 4 degrees, or about -3 degrees to about 3 degrees, or about -2 degrees to about 2 degrees, or about -1 degrees to about 1 degrees, or about 0 degrees, or 0 degrees.

As shown, the strips 400 may be separated one from another by a non-termini seam 600 that is a gap seam 602. It is to be appreciated, and will be illustrated hereinafter, for example, in FIG. 15, FIG. 16, and FIG. 17, that the non-termini seams 600 between each strip 400 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of non-termini seams 600 may be employed. Since a support layer 200 formed from strips 400 internally wrapped around a support layer 200, as illustrated in FIG. 7A and FIG. 7B does not repeatedly spiral around the support layer 200, each of the plurality of strips 400 may comprise a termini seam 500. As illustrated, the termini seams 500 may be abutting seams 501. It is to be appreciated that the termini seams 500 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of termini seam 500 may be employed. In other words, different strips may employ different types of termini seams.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place the endless support layer with optionally applied associating material, bonding layer or modifying material onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate the orthogonal wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are substantially parallel to the cross direction of the support layer. According to various embodiments, it is possible to continue contacting the structuring layer with the support layer until the structuring layer reaches the first MD parallel edge of the support layer. According to various embodiments, it is possible to fold the structuring layer around the edge of the support layer and continue the orthogonal wrap by contacting the structuring layer with the backside or the inside or inner core surface of the support layer, maintaining substantially parallel with the support layer cross direction. According to various embodiments, it is possible to continue the wrap across the back side surface, folding the structuring layer around the second MD parallel edge of the support layer coming around to the top face of the support layer and up to the first termini edge plane of the structuring layer material. According to various embodiments, it is possible to cut the structuring layer material to create a second termini edge that when in contact with the support layer creates a 1.2mm gap seam with the first structuring layer termini end. According to various embodiments, it is possible to treat the entire first orthogonal wrap of structing material in contact with the support layer to bond the two layers. According to various embodiments, it is possible to align the next consecutive wrap of the structuring layer so that the non-termini ends of the first orthogonal wrap to create a 1 to 1.2mm gap seam with the second orthogonal wrap and the first termini end of the second wrap are parallel with the first termini end of the first wrap. Optionally, this seam may be 0.5 to 4mm. According to various embodiments, it is possible to continue wrapping the structuring layer parallel to the cross direction and with a 1 to 1.2mm gap seam with the prior wraps second non-termini edge until the structuring layer overlaps with the first termini edge of the second wrap. According to various embodiments, it is possible to cut the structuring layer material like the first orthogonal wrap, leaving a 1.2mm gap seam between the first and second termini edges of the second orthogonal wrap. According to various embodiments, it is possible to continue with consecutive wraps with 1-1.2mm gap seams between orthogonal wraps and 1.2mm termini edges until the wraps meet up with the first non-termini edge of the first wrap. Optionally, the termini edge seams the non-termini edge seams may be of different width between the orthogonal wraps. According to various embodiments, it is possible to treat each orthogonal wrap of structing material in contact with the support layer to bond the two layers. During the orthogonal wraps, when the structuring layer wraps on the backside of the support layer touching the mandrel, it is possible to index the support layer across the mandrels to access the backside of the support layer. Optionally it is possible to temporarily tape each orthogonal wrap to hold in place and treat the entire structuring and support layers so that the outer, inner and middles layers bond together after completing all the orthogonal wraps to fill the belt. This will produce a belt with a structuring layer on both the inner and outer surface of the support layer.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place an endless loop of non-bonding protective material of the same width and length as the support layer onto two mandrels. According to various embodiments, it is possible to place the endless support layer with optionally applied associating material, bonding layer or modifying material over this on the two mandrels so that the support and non-bonding layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate the orthogonal wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are substantially parallel to the cross direction of the support layer. According to various embodiments, it is possible to continue contacting the structuring layer with the support layer until the structuring layer reaches the first MD parallel edge of the support layer. According to various embodiments, it is possible to fold the structuring layer around the edge of the support layer and the non-bonding layer and continue the orthogonal wrap by contacting the non-bonding layer on the inner backside of the support layer, maintaining non termini structuring layer edges substantially parallel with the cross direction of the support layer. According to various embodiments, it is possible to continue the wrap across the back side non-bonding layer surface, folding the structuring layer around the second MD parallel edge of the non-bonding layer and the support layer coming around to the top face of the support layer and up to the first termini edge of the structuring layer material. According to various embodiments, it is possible to cut the structuring layer material to create a second termini edge that when in contact with the support layer creates an abut seam with the first structuring layer termini end. According to various embodiments, it is possible to treat the outer surface of the orthogonal wrap of structing material in contact with the support layer to bond the two layers. According to various embodiments, it is possible to align the next consecutive orthogonal wrap of the structuring layer so that the non-termini ends of the first orthogonal wrap to create a .8 mm gap seam with the second orthogonal wrap and the first termini end of the second wrap are parallel with the first termini end of the first wrap. According to various embodiments, it is possible to continue wrapping the structuring layer parallel to the cross direction and with a 0.8mm gap seam with the prior wraps second non-termini edge until the structuring layer overlaps with the first termini edge of the second wrap. According to various embodiments, it is possible to cut the structuring layer material like the first orthogonal wrap, leaving a 0.5mm overlap seam between the first and second termini edges of the second orthogonal wrap. According to various embodiments, it is possible to treat the outer surface of this orthogonal wrap of structing material in contact with the support layer to bond the two layers. According to various embodiments, it is possible to continue with consecutive wraps with 0.8mm gap seams between orthogonal wraps and termini edges and treatment for bonding until the wraps meet up with the first non-termini edge of the first wrap. According to various embodiments, it is possible to cut this wrap of structuring layer to a width to maintain 0.8mm gap seam between the first non-termini edge of the final orthogonal wrap and the second non-termini edge of the second to last orthogonal wrap and a 0.8mm gap seam between the second non-termini edge of the final orthogonal wrap and the first non-termini edge of the first orthogonal wrap. During the orthogonal wraps, when the structuring layer wraps on the backside of the support layer and the non-bonding layer touching the mandrel, it is possible to index the support layer and non-bonding layer across the mandrels to access the backside of the support layer and the non-bonding surface. According to various embodiments, it is possible to remove the non-bonded structuring layer wrapped about the backside surface of the support layer & non-bonding structuring layer by cutting the material along the MD edges of the support layer. According to various embodiments, it is possible to remove the non-bonded structuring layer material and the non-bonding layer. This will produce a belt with a structuring layer on the outer surface of the support layer.

FIG. 8A and FIG. 8B cooperate to illustrate a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300. The structuring layer 300 may comprise one or more strips 400 internally and spirally wrapped in a cross direction CD about the support layer 200 and disposed in a facing relationship with the support layer 200. FIG. 8A is a schematic perspective view. FIG. 8B is a schematic perspective view of a portion of the web material structuring belt 100 of FIG. 8A. Each strip 400 may have a major axis 440 that is at an angle 441 relative to the machine direction.

It is to be appreciated that the angle 441 may be any angle, but that to allow the strip 400 to spiral around the support layer 200, the angle 441 may be any angle other than 0 degrees, 90 degrees, or -90 degrees. For example, the angle 441 may be in a range of from greater than 0 degrees to less than 90 degrees, or greater than about 0 degrees to less than about 90 degrees, or about 3 degrees to about 80 degrees, or about 6 degrees to about 70 degrees, or about 8 degrees to about 60 degrees, or about 10 degrees to about 50 degrees, or about 12 degrees to about 45 degrees, or about 15 degrees to about 35 degrees, or about 18 degrees to about 25 degrees, or about 20 degrees to about 25 degrees, or about 22.5 degrees.

Since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. The angle 441 may vary for adjacent strips 400 and even in a case where a single strip 400 is repeatedly wrapped around the support layer 200 the angle 441 may vary for adjacent portions of the same strip 400. As shown, the strips 400 may be separated one from another by a non-termini seam 600. The non-termini seam 600 may be a gap seam 602. It is to be appreciated that the non-termini seams 600 between each strip 400 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of non-termini seams 600 may be employed. Termini portions of a strip 400 or plurality of strips 400 may comprise a termini seam 500. The termini seam 500 may be an abutting seam 501. It is to be appreciated that the termini seams 500 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of termini seam 500 may be employed. In other words, different strips may employ different types of termini seams.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place an endless support layer with optionally applied associating material, bonding layer or modifying material onto two mandrels so that the support layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate the spiral wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are rotated 5 degrees off parallel from the support layer cross direction. Optionally the edges may be rotated 0 to 45 degrees off parallel. According to various embodiments, it is possible to continue contacting and translating the structuring layer in a spiral wrap with the support layer until the structuring layer reaches the first MD edge of the support layer. According to various embodiments, it is possible to fold the structuring layer around the edge of the support layer and continue the translation for spiral wrap by contacting the structuring layer with the backside of the support, maintaining the 5 degree angle. According to various embodiments, it is possible to continue the translation and spiral wrap across the back side surface, folding the structuring layer around the second MD edge of the support layer coming around to the top face of the support layer and up to the first termini edge plane of the first structuring layer spiral wrap continuing to translate the structuring layer so the second spiral wrap of the structuring layer first non-termini ends create a 1.6mm gap seam with the second non-termini edges of the first spiral wrap. Optionally this seam may be 0.5 to 4mm. According to various embodiments, it is possible to continue translating to spiral wrap the structuring layer at 5 degrees from the cross direction and 1.6mm gap seam from the prior cycle until the structuring layer makes a final translation spiral to meet back up with the first termini edge. During the progress of the spiral wind cycle when the structuring layer wraps on the backside of the support layer touching the mandrel, it is possible to index the support layer around the mandrels to access the backside of the support layer. According to various embodiments, it is possible to treat the structuring and support layers so that the outer, inner and middles layers bond together. This will produce a belt with a structuring layer on both the inner and outer surface of the support layer.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place an endless loop of non-bonding protective material of the same width and length as the support layer onto two mandrels. According to various embodiments, it is possible to place the endless support layer with optionally applied associating material, bonding layer or modifying material on the two mandrels so that the support and non-bonding layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate the spiral wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are rotated 5 degrees from the support layer cross direction. Optionally the edges may be rotated 0 to 45degrees off from the cross direction. According to various embodiments, it is possible to continue contacting and translating the structuring layer in a spiral wrap with the support layer until the structuring layer reaches the first MD edge of the support layer and continue the translation for spiral wrap by contacting the structuring layer with the backside of the non-bonding layer, maintaining the 5 degree angle. According to various embodiments, it is possible to continue the translation and spiral wrap across the non-bonding surface, folding the structuring layer around the second MD edge of the support layer coming around to the top face of the support layer and up to the first termini edge plane of the first structuring layer spiral wrap continuing to translate the structuring layer so the second spiral wrap of the structuring layer first non-termini ends create a 1.6mm gap seam with the second non-termini edges of the first spiral wrap. Optionally this seam may be 0.5 to 4mm. According to various embodiments, it is possible to continue translating to spiral wrap the structuring layer at 5 degrees from the cross direction and 1.6mm gap seam from the prior cycle until the structuring layer makes a final translation spiral to meet back up with the first termini edge. During the wind cycle when the structuring layer wraps on the backside of the support layer contacting the non-bonding layer and touching the mandrel, it is possible to index the support layer and non-bonding layer across the mandrels to access the backside of the support layer and contact the non-bonding layer. According to various embodiments, it is possible to treat outer surface the structuring and support layers to bond the layers together. According to various embodiments, it is possible to remove the non-bonded structuring layer wrapped about the backside surface of the support layer by cutting the material along the MD edge of the support layer. According to various embodiments, it is possible to remove the non-bonded structuring layer material and the non-bonding layer. This will produce a belt with a structuring layer on the outer surface of the support layer.

FIG. 9A and FIG. 9B cooperate to illustrate a web material structuring belt 100 comprising a support layer 200 and structuring layer 300. The structuring layer 300 may comprise one or more strips 400 externally wrapped in a cross direction CD about the support layer 200 and disposed in a facing relationship with the support layer 200. FIG. 9A is a schematic perspective view. FIG. 9B is a schematic perspective view of a portion of the web material structuring belt 100 of FIG. 9A after external flap folds 480 are cut away to expose cut ends 481 of the structuring layers 300. Each strip 400 may have a major axis 440 that is disposed perpendicularly or substantially perpendicularly with the machine direction MD, such that an angle 441 between the major axis 440 and the machine direction is 90 degrees, or about 90 degrees, or in a range of from about 85 degrees to about 90 degrees, or about 86 degrees to about 90 degrees, or about 87 degrees to about 90 degrees or about 88 to 90 or about 89 to 9 or about -90, or about -86 to -90, or about -87 to about -90 or about -88 to about -90 or about -89 to about -90Since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. The angle 442 between the major axis 440 of each strip and the cross-direction may be from -5 degrees to 5 degrees, or about -5 degrees to about 5 degrees, or about -4 degrees to about 4 degrees, or about -3 degrees to about 3 degrees, or about -2 degrees to about 2 degrees, or about -1 degrees to about 1 degrees, or about 0 degrees, or 0 degrees.

As shown, the strips 400 may be separated one from another by a non-termini seam 600 that is a gap seam 602. It is to be appreciated that the non-termini seams 600 between each strip 400 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of non-termini seams 600 may be employed. Since a support layer 200 formed from strips 400 internally wrapped around a support layer 200, as illustrated in FIG. 7A and FIG. 7B does not repeatedly spiral around the support layer 200, each of the plurality of strips 400 may comprise a termini seam 500. As illustrated, the termini seams 500 may be abutting seams 501. It is to be appreciated that the termini seams 500 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of termini seam 500 may be employed. In other words, different strips may employ different types of termini seams. As shown in FIG. 9A, it may be beneficial according to various embodiments if any termini seams 500 are positioned at the external flap folds 480 so that they may be removed from the final web material structuring belt 100, as shown in FIG. 9B.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. The minimum length of structuring layer needed may be calculated by dividing the out facing surface area of the support layer by the width of the structuring layer plus the non-termini gap seam distance. According to various embodiments, it is possible to create or provide an additional 10% to account for non-support layer coverage between the upper and lower surface of the support layer (480). According to various embodiments, it is possible to place an endless loop of non-bonding protective material of the same width and length as the support layer onto two mandrels. Optionally it is possible to apply an associating material, bonding layer or modifying material to the support layer. According to various embodiments, it is possible to place the endless support layer over the non-bonding layer on the two mandrels so that the support and non-bonding layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate the first cycle of orthogonal wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are substantially parallel with the support layer cross direction. According to various embodiments, it is possible to continue to orthogonally wrap the structuring layer material around the support layer passing over an MD edge of the support layer down to the next MD edge of the support layer then around the outer surface of the lower support layer level and back up to the top level and up past the first termini edge plane of the structuring layer material. With the structuring layer overlapping itself, cut through both structuring layer layers with a cut 45 degrees from perpendicular with the non-termini edges of the structuring layer material, to create an abut seam on a 45 degree angle. Optionally, the seam may be cut to have a gap, abut or overlap or combination of seam types. Optionally the seam may be cut between 45 to 0 degrees from parallel to the cross direction of the support layer. According to various embodiments, it is possible to treat the entire first orthogonal wrap of structing material in contact with the support layer to bond the two layers. Next it is possible to increment a new length of structuring material layer over 1.5mm to create a gap seam between the second non-termini edge of the first wrap and the first non-termini edge of the second wrap. According to various embodiments, it is possible to place the termini edge of the second wrap approximately 1 inch further in the cross direction than the first wrap termini seam. Optionally the first and second seams may be in line or up to 10 feet apart. According to various embodiments, it is possible to maintain substantially parallel placement of the second structuring layer wrap with the edge of the first wrap second non-termini edge. When this wrap of structuring layer overlaps with itself, it is possible to cut through both structuring layers with a cut 45 degrees from perpendicular with the non termini edges of the structuring layer material, to create an structuring layer abut seam on a 45 degree angle. Optionally, the seam may be cut to have a gap, abut or overlap or combination of seam types. Also optionally the seam may be cut between 45 to 0 degrees from parallel to the cross direction of the support layer. According to various embodiments, it is possible to treat the second orthogonal wrap of structing material in contact with the support layer to bond the layers. According to various embodiments, it is possible to continue with orthogonal wrap segments offset by 1.5mm gap seam and termini abut seams offset by approximately 1 inch in the cross machine direction from the previous wrap and bonding the structuring and support layers of the wrap until the structuring layer until the entire endless loop has been cycled. According to various embodiments, it is possible to cut away the structuring layer material that extends past the support layer on all the MD edges of the support layer. According to various embodiments, it is possible to remove the material and the non-bonding protective material. Optionally the structuring and support layer may be treated to the bond the layers after all the wraps have been completed by temporarily affixing the orthogonal wrap termini edges across the belt with tape until the bonding process is begun.

FIG. 10A and FIG. 10B cooperate to illustrate a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300. The structuring layer 300 may comprise one or more strips 400 externally and spirally wrapped in a cross direction CD about the support layer 200 and disposed in a facing relationship with the support layer 200. As shown, a structuring layer 300 may comprise one or more strips 400 internally and spirally wrapped in a cross direction CD about a support layer 200. FIG. 10A is a schematic perspective view. FIG. 10B is a schematic perspective view of a portion of the web material structuring belt 100 of FIG. 10A after external flap folds 480 are cut away to expose cut ends 481 of the structuring layers 300. Each strip 400 may have a major axis 440 that is at an angle 441 relative to the machine direction. It is to be appreciated that the angle 441 may be any angle, but that to allow the strip 400 to spiral around the support layer 200, the angle 441 may be any angle other than 0 degrees, 90 degrees, or -90 degrees. For example, the angle 441 may be in a range of from greater than 0 degrees to less than 90 degrees, or greater than about 0 degrees to less than about 90 degrees, or about 3 degrees to about 80 degrees, or about 6 degrees to about 70 degrees, or about 8 degrees to about 60 degrees, or about 10 degrees to about 50 degrees, or about 12 degrees to about 45 degrees, or about 15 degrees to about 35 degrees, or about 18 degrees to about 25 degrees, or about 20 degrees to about 25 degrees, or about 22.5 degrees, or the negative values of the degrees of this sentence.

Since the cross direction CD is perpendicular to the machine direction, the value of the angle 442 between the major axis 440 and the cross direction CD follows mathematically based on specification of the angle 441 or vice versa. The angle 441 may vary for adjacent strips 400 and even in a case where a single strip 400 is repeatedly wrapped around the support layer 200 the angle 441 may vary for adjacent portions of the same strip 400. As shown, the strips 400 may be separated one from another by a non-termini seam 600. The non-termini seam 600 may be a gap seam 602. It is to be appreciated that the non-termini seams 600 between each strip 400 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of non-termini seams 600 may be employed. Termini portions of a strip 400 or plurality of strips 400 may comprise a termini seam 500. The termini seam 500 may be an abutting seam 501. It is to be appreciated that the termini seams 500 may be any type of seam described herein, including but not limited to abutting seams, gap seams, overlapping seams, and interlocking seams. Additionally, any combination of termini seam 500 may be employed. In other words, different strips may employ different types of termini seams. As shown in FIG. 10A, it may be beneficial according to various embodiments if any termini seams 500 are positioned at the external flap folds 480 so that they may be removed from the final web material structuring belt 100, as shown in FIG. 10B.

According to various embodiments, it is possible to create a structuring layer material narrower than the width of the support layer. According to various embodiments, it is possible to place an endless loop of non-bonding protective material of the same width and length as the support layer onto two mandrels. Optionally, it is possible to apply an associating material, bonding layer or modifying material to the support layer. According to various embodiments, it is possible to place the endless support layer over the non-bonding layer on the two mandrels so that the support and non-bonding layer is lightly tensioned with outward pressure on two opposing ends of the support layer loop and the outer surface of the support layer is free from contact with the mandrels. According to various embodiments, it is possible to initiate the spiral wrap by positioning the structuring layer and the support layer in contact with one another so that the structuring layer non-termini edges are rotated +2.5 degrees off the support layer cross direction. Optionally the material may be rotated +0.5 to +44.5 or -0.5 to -44.5 degrees from the support layer cross direction. According to various embodiments, it is possible to continue to spirally wrap the structuring layer material around the support layer passing over an MD edge of the support layer down to the next MD edge of the support layer then around the outer surface of the lower support layer level and back up to the top level and up to the first termini edge plane of the structuring layer material. According to various embodiments, it is possible to align this second spiral wrap cycle of the structuring layer so that the non-termini ends of the first wrap create a 1mm gap seam with this second wrap. According to various embodiments, it is possible to continue wrapping the structuring layer at 2.5 degrees from the cross direction and 1mm gap seam the prior spiral wrap cycle second non-termini edge and the current spiral wrap cycle first non-termini edge until the structuring layer touches or overlaps with the first spiral wrap cycle termini edge. According to various embodiments, it is possible to treat the structuring material in contact with the support layer to bond the two layers. According to various embodiments, it is possible to cut away the structuring layer material that extends past the support layer on all the MD edges of the support layer. According to various embodiments, it is possible to remove the material and the non-bonding protective material.

FIG. 11 is a schematic perspective view a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300 disposed in a facing relationship with the support layer 200. The structuring layer 300 comprises a plurality of strip portions 462, which may be applied to the support layer 200 by wrapping a strip 400 as shown in FIG. 2D about the support layer 200 according to any of the methods described herein.

FIG. 12 is a schematic perspective view a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300 disposed in a facing relationship with the support layer 200. The structuring layer 300 comprises a combination of strips wrapped in different orientations. FIG. 12 illustrates a combination of machine direction MD wrapping and internal cross direction CD wrapping. It is to be appreciated that any combination of the various wrappings may be employed. Any combination of machine direction MD wrapping, cross direction CD wrapping, spiral wrapping, internal, or external wrapping may be employed. Any of the techniques disclosed herein may be combined to produce a web material structuring belt 100.

FIG. 13, FIG. 14, FIG. 15, and FIG. 16 cooperate to illustrate some variations on web material structuring belt 100 comprising a support layer 200 that combine various wrap angles 441, 442 and various non-termini seams 600. For ease of comparison, these figures all show strips 400 externally wrapped in a machine direction MD. It is to be appreciated that the exemplified variations and combinations of various wrap angles 441, 442 and non-termini seams 600 are not limited to machine direction MD wraps, but may be used in these and other combinations in cross direction CD wraps. FIG. 13 is a schematic perspective view a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300, comprising a plurality of strips 400 disposed in a facing relationship with the support layer 200. The non-termini seams 600 are all gap seams 602. FIG. 13 also illustrates a combination of strips 400 in which some strips are wrapped in a spirally manner about the support layer 200, while others are not. FIG. 14 is a schematic top view of a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300, comprising a plurality of strips 400 disposed in a facing relationship with the support layer 200, showing an abutting seam 601 between non-termini portions 420a, 420b of at least one structuring layer 300. FIG. 15 is a schematic top view of a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300, comprising a plurality of strips 400 disposed in a facing relationship with the support layer 200, showing an x-y interlocking seam 605 between non-termini portions 420a, 420b of at least one structuring layer 300. FIG. 16 is a schematic top view of a web material structuring belt 100 comprising a support layer 200 and a structuring layer 300, comprising a plurality of strips 400 disposed in a facing relationship with the support layer 200, showing an overlap seam 603 between non-termini portions 420a, 420b of at least one structuring layer 300.

As best illustrated in FIGS. 5B, 6B, 7B, and 8B, but as is applicable to all embodiments described herein, a gap seam 602 may have a width spanning the distance between adjacent strips 400. This gap or valley between the structuring layers 300, embodied as strips 400, may have a gap width GW. The gap width GW may be from about 1/64 in (0.0397 cm) to about 2 in (5.08 cm), or about 1/32 in (0.0794 cm) to about 1 in (2.54 cm), or about 1/32 in (0.0794 cm) to about 0.75 in (1.905 cm), or about 1/16 in (0.1588 cm) to about 1/2 in (1.27 cm). The gap seam 602 may effectively become part of the overall structuring layer 300 in that it may be used to add a texture, a contour, a protrusion, a trough or a shape to a material disposed on the web material structuring belt 100.

As will be appreciated by those having ordinary skill in the art, various embodiments solve a variety of problems associated with winding belts. Providing winding belts from a narrower width structuring layer may provide material, cost, and pattern opportunities versus a full width structuring layer. Heretofore, winding belts, tended to create more seams that may create a higher probability for a discontinuity that is disadvantageous for a commercial-scale process or a commercially-acceptable product. It is has been discovered that a controlled gap seam, especially on the increased seam lengths of the non-terminal portions, will not have high thickness or low permeability issues that lead to the process and product problems. Various embodiments may reduce discontinuities so as to minimize process and product discontinuities that may lead to needing to run lower speeds or making bad product.

Various embodiments may control the type of seams so that they are predominately gap seams. Various embodiments may control where and how the seams in the machine direction MD and the cross direction CD are located using similar or disparate sized pieces of structuring strips. Various embodiments may employ gapping seams to create a “fire break,” where using structuring layer strips that remain independent of contact from each other, prevents a tear, hole, delamination, or other failure in the structuring layer from continuing to grow across the entire belt. Various embodiments may spirally wind the structuring strips in the cross direction CD, thus isolating individual segments across the machine direction MD, which may be the primary direction of strain for the belt. Without being bound by theory, it is thought that by segmenting the strips and keeping them independent of each other, the MD strain can be carried by the support layer, thus reducing strain on the structuring layer and any association, associating layer or bonding between the support and structuring layer. According to various embodiments, the gap seam may be part of the overall pattern of continuous or discontinuous structuring layers. According to various embodiments, a continuous pattern layer, where there is a continuous network of structuring layer material forming a pattern, may enable a semi-continuous overall pattern by separating the continuous network strips with a discontinuous gap seam, while a discontinuous pattern layer where the structuring layer material is not a continuous network may enable maintaining a discontinuous overall pattern by creating a continuous discontinuous network with the gap seam.

COMBINATIONS

Various embodiments relate to:

1. A web material structuring belt comprising a support layer; and a structuring layer comprising one or more strips of structuring layer material, wherein two or more non-termini portions of the one or more strips of structuring layer material form a non-termini portion structuring layer material gap seam.

2. The web material structuring belt according to paragraph 1 wherein at least one of the one or more strips of structuring layer material comprises a spirally wound structuring layer material strip.

3. The web material structuring belt according to paragraph 2 wherein the spirally wound structuring layer material strip comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s machine direction.

4. The web material structuring belt according to any of paragraphs 2 or 3 wherein the spirally wound structuring layer material strip comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

5. The web material structuring belt according to any of paragraphs 2 to 4 wherein the web material structuring belt comprises two or more spirally wound structuring layer material strips.

6. The web material structuring belt according to paragraph 5 wherein at least two of the two or more spirally wound structuring layer material strips comprise major axes that are oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s machine direction.

7. The web material structuring belt according to any of paragraphs 5 or 6 wherein at least two of the two or more spirally wound structuring layer material strips comprise major axes that are oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

8. The web material structuring belt according to any of paragraphs 5 to 7 wherein at least one of the two or more spirally wound structuring layer material strips comprises a major axis that is oriented at an angle of from 0˚ to 45˚ relative to the web material structuring belt’s machine direction and at least another of the two or more spirally wound structuring layer material strips comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

9. The web material structuring belt according to any of paragraphs 5 to 8 wherein at least two of the two or more spirally wound structuring layer material strips comprise major axes that are oriented at different angles relative to the machine direction.

10. The web material structuring belt according to any of paragraphs 5 to 9 at least two of the two or more spirally wound structuring layer material strips comprise at least two termini portions that form a termini portion structuring layer material seam.

11. The web material structuring belt according to paragraph 10 wherein the termini portion structuring layer material seam comprises an abut seam.

12. The web material structuring belt according to any of paragraphs 10 or 11 wherein the termini portion structuring layer material seam comprises a gap seam.

13. The web material structuring belt according to any of paragraphs 10 to 12 wherein the termini portion structuring layer material seam comprises an overlap seam.

14. The web material structuring belt according to paragraph 13 wherein the overlap seam is an x-y interlocking overlap seam.

15. The web material structuring belt according to any of paragraphs 13 or 14 wherein the overlap seam is a z-interlocking overlap seam.

16. The web material structuring belt according to any of paragraphs 10 to 15 wherein the termini portion structuring layer material seam comprises a major axis that is oriented at an angle of from 0˚ to 45˚ relative to the web material structuring belt’s machine direction.

17. The web material structuring belt according to any of paragraphs 10 to 16 wherein the termini portion structuring layer material seam comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

18. The web material structuring belt according to any of paragraphs 1 to 17 wherein at least one of the one or more strips of structuring layer material comprises a spirally wound structuring layer material strip and at least one of the one or more strips of structuring layer material comprises a non-spirally wound structuring layer material strip.

19. The web material structuring belt according to paragraph 18 wherein the spirally wound structuring layer material strip comprises a major axis that is oriented at an angle of from 0˚ to 45˚ relative to the web material structuring belt’s machine direction.

20. The web material structuring belt according to any of paragraphs 18 or 19 wherein the spirally wound structuring layer material strip comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

21. The web material structuring belt according to any of paragraphs 18 to 20 wherein the web material structuring belt comprises two or more spirally wound structuring layer material strips.

22. The web material structuring belt according to paragraph 21 wherein at least two of the two or more spirally wound structuring layer material strips comprise major axes that are oriented at an angle of from 0˚ to 45˚ relative to the web material structuring belt’s machine direction.

23. The web material structuring belt according to any of paragraphs 21 or 22 wherein at least two of the two or more spirally wound structuring layer material strips comprise major axes that are oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

24. The web material structuring belt according to any of paragraphs 21 to 23 wherein at least one of the two or more spirally wound structuring layer material strips comprises a major axis that is oriented at an angle of from 0˚ to 45˚ relative to the web material structuring belt’s machine direction and at least another of the two or more spirally wound structuring layer material strips comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

25. The web material structuring belt according to any of paragraphs 21 to 24 wherein at least two of the two or more spirally wound structuring layer material strips comprise major axes that are oriented at different angles relative to the machine direction.

26. The web material structuring belt according to any of paragraphs 21 to 25 at least two of the two or more spirally wound structuring layer material strips comprise at least two termini portions that form a termini portion structuring layer material seam.

27. The web material structuring belt according to paragraph 26 wherein the termini portion structuring layer material seam comprises an abut seam.

28. The web material structuring belt according to any of paragraphs 26 or 27 wherein the termini portion structuring layer material seam comprises a gap seam.

29. The web material structuring belt according to any of paragraphs 26 to 28 wherein the termini portion structuring layer material seam comprises an overlap seam.

30. The web material structuring belt according to paragraph 29 wherein the overlap seam is an x-y interlocking overlap seam.

31. The web material structuring belt according to any of paragraphs 29 or 30 wherein the overlap seam is a z-interlocking overlap seam.

32. The web material structuring belt according to any of paragraphs 26 to 31 wherein the termini portion structuring layer material seam comprises a major axis that is oriented at an angle of from 0˚ to 45˚ relative to the web material structuring belt’s machine direction.

33. The web material structuring belt according to any of paragraphs 26 to 32 wherein the termini portion structuring layer material seam comprises a major axis that is oriented at an angle of from negative 45˚ to positive 45˚ relative to the web material structuring belt’s cross machine direction.

34. The web material structuring belt according to paragraph 18 wherein the non-spirally wound structuring layer material strip comprises at least two termini portions that form a termini portion structuring layer material seam.

35. The web material structuring belt according to paragraph 34 wherein the termini portion structuring layer material seam comprises an abut seam.

36. The web material structuring belt according to any of paragraphs 34 or 35 wherein the termini portion structuring layer material seam comprises a gap seam.

37. The web material structuring belt according to any of paragraphs 34 to 36wherein the termini portion structuring layer material seam comprises an overlap seam.

38. The web material structuring belt according to paragraph 37 wherein the overlap seam is an x-y interlocking overlap seam.

39. The web material structuring belt according to any of paragraphs 37 or 38 wherein the overlap seam is a z-interlocking overlap seam.

40. The web material structuring belt according to paragraph 18 wherein the structuring layer comprises two or more non-spirally wound structuring layer material strips.

41. The web material structuring belt according to any of paragraphs 1 to 40 wherein three or more non-termini portions of the one or more strips of structure layer material form two or more non-termini portion structuring layer material gap seams.

42. The web material structuring belt according to any of paragraphs 1 to 41 wherein at least one of the one or more strips of structuring layer material comprise one or more termini portions of the one or more strips of structuring layer material that form one or more termini portion structuring layer material seams.

43. The web material structuring belt according to any of paragraphs 1 to 42 wherein at least one of the one or more strips of structuring layer material comprises a non-spirally wound structuring layer material strip.

44. The web material structuring belt according to paragraph 43 wherein the non-spirally wound structuring layer material strip comprises at least two termini portions that form a termini portion structuring layer material seam.

45. The web material structuring belt according to paragraph 44 wherein the termini portion structuring layer material seam comprises an abut seam.

46. The web material structuring belt according to any of paragraphs 44 or 45 wherein the termini portion structuring layer material seam comprises a gap seam.

47. The web material structuring belt according to any of paragraphs 44 to 46 wherein the termini portion structuring layer material seam comprises an overlap seam.

48. The web material structuring belt according to paragraph 47 wherein the overlap seam is an x-y interlocking overlap seam.

49. The web material structuring belt according to any of paragraphs 47 or 48 wherein the overlap seam is a z-interlocking overlap seam.

50. The web material structuring belt according to any of paragraphs 43to 49 wherein the structuring layer comprises two or more non-spirally wound structuring layer material strips.

51. The web material structuring belt according to paragraph 50 wherein at least two of the two or more non-spirally wound structuring layer material strips each comprises at least two termini portions that form a termini portion structuring layer material seam.

52. The web material structuring belt according to paragraph 51 wherein the termini portion structuring layer material seam comprises an abut seam.

53. The web material structuring belt according to any of paragraphs 51 or 52 wherein the termini portion structuring layer material seam comprises a gap seam.

54. The web material structuring belt according to any of paragraphs 51 to 53 wherein the termini portion structuring layer material seam comprises an overlap seam.

55. The web material structuring belt according to paragraph 54 wherein the overlap seam is an x-y interlocking overlap seam.

56. The web material structuring belt according to any of paragraphs 54 or 55 wherein the overlap seam is a z-interlocking overlap seam.

57. The web material structuring belt according to any of paragraphs 51 to 56 wherein at least one non-spirally wound structuring layer material strip comprises a first termini portion structuring layer material seam and at least one spirally wound structuring layer material strip comprises a second termini portion structuring layer material seam that is different from the first termini portion structuring layer material seam.

58. The web material structuring belt according to paragraph 57 wherein the first termini portion structuring layer material seam comprises an abut seam and the second termini portion structuring layer material seam comprises a gap seam.

59. The web material structuring belt according to any of paragraphs 57 or 58 wherein the first termini portion structuring layer material seam comprises an abut seam and the second termini portion structuring layer material seam comprises an overlap seam.

60. The web material structuring belt according to any of paragraphs 57 to 59 wherein the first termini portion structuring layer material seam comprises a gap seam and the second termini portion structuring layer material seam comprises an overlap seam.

61. The web material structuring belt according to any of paragraphs 57 to 60 wherein the first termini portion structuring layer material seam and the second termini portion structuring layer material seam are present within the web material structuring belt at an adjacent separation distance from each other of 50% or less of the length of the web material structuring belt.

62. The web material structuring belt according to any of paragraphs 57 to 61 wherein the first termini portion structuring layer material seam and the second termini portion structuring layer material seam are present within the web material structuring belt at an adjacent separation distance from each other of less than 50% of the length of the web material structuring belt.

63. The web material structuring belt according to any of paragraphs 57 to 62 wherein the first termini portion structuring layer material seam and the second termini portion structuring layer material seam are present within the web material structuring belt at an adjacent separation distance of less than 25% of the length of the web material structuring belt.

64. The web material structuring belt according to any of paragraphs 57 to 63 wherein the first termini portion structuring layer material seam and the second termini portion structuring layer material seam are present within the web material structuring belt at an adjacent separation distance of less than 10% of the length of the web material structuring belt.

65. The web material structuring belt according to any of paragraphs 57 to 64 wherein the first termini portion structuring layer material seam and the second termini portion structuring layer material seam are present within the web material structuring belt at an adjacent separation distance of less than 5% of the length of the web material structuring belt.

66. The web material structuring belt according to any of paragraphs 57 to 65 wherein the first termini portion structuring layer material seam and the second termini portion structuring layer material seam are present within the web material structuring belt at an adjacent separation distance of about 0% of the length of the web material structuring belt.

67. The web material structuring belt according to any of paragraphs 1 to 66 wherein the support layer exhibits an air perm of greater than 300 scfm.

68. The web material structuring belt according to any of paragraphs 1 to 67 wherein the support layer comprises a woven fabric.

69. The web material structuring belt according to paragraph 68 wherein the support layer comprises two or more layers of fibrous elements.

70. The web material structuring belt according to any of paragraphs 1 to 69 wherein the structuring layer material gap seam is associated with the support layer.

71. The web material structuring belt according to paragraph 70 wherein the non-termini structuring layer material gap seam extends into the support layer.

72. The web material structuring belt according to paragraph 71 wherein the non-termini structuring layer material gap seam extends into, but less than entirely through the support layer.

73. The web material structuring belt according to any of paragraphs 71 or 72 wherein the non-termini structuring layer material gap seam extends through the support layer.

74. The web material structuring belt according to any of paragraphs 1 to 73 wherein the non-termini structuring layer material gap seam comprises at least one gap seam portion that is associated with the support layer.

75. The web material structuring belt according to paragraph 74 wherein the at least one gap seam portion extends into the support layer.

76. The web material structuring belt according to paragraph 75 wherein the at least one gap seam portion extends into, but less than entirely through the support layer.

77. The web material structuring belt according to paragraph 76 wherein the at least one gap seam portion extends through the support layer.

78. The web material structuring belt according to any of paragraphs 1 to 77 wherein the non-termini structuring layer material gap seam comprises at least two gap seam portions that are associated with the support layer.

79. The web material structuring belt according to paragraph 78 wherein the at least two gap seam portions extend into the support layer.

80. The web material structuring belt according to paragraph 79 wherein the at least two gap seam portions extend into, but less than entirely through the support layer.

81. The web material structuring belt according to any of paragraphs 79 or 80 wherein the at least two gap seam portions extend through the support layer.

82. The web material structuring belt according to any of paragraphs 1 to 81 wherein the structuring layer comprises a pattern.

83. The web material structuring belt according to paragraph 82 wherein the pattern is a non-random repeating pattern.

84. The web material structuring belt according to any of paragraphs 1 to 83 wherein the structuring layer comprises a polymer.

85. The web material structuring belt according to any of paragraphs 1 to 84 wherein the structuring layer comprises a film.

86. The web material structuring belt according to any of paragraphs 1 to 85wherein the structuring layer comprises a foam.

87. The web material structuring belt according to any of paragraphs 1 to 86 wherein the structuring layer comprises a resin.

88. The web material structuring belt according to any of paragraphs 1 to 87 wherein the structuring layer is mechanically entangled with the support layer.

89. The web material structuring belt according to any of paragraphs1 to 88 wherein at least one non-termini structuring layer material gap seam portion of the structuring layer is associated with the support layer.

90. The web material structuring belt according to paragraph 89 wherein the at least one non-termini structuring layer material gap seam portion of the structuring layer extends into the support layer.

91. The web material structuring belt according to any of paragraphs 1 to 90 wherein the non-termini portion structuring layer material gap seam is connected to a termini portion structuring layer material gap seam at an angle of 90˚.

92. The web material structuring belt according to any of paragraphs 1 to 91 wherein the non-termini portion structuring layer material gap seam is connected to a termini portion structuring layer material gap seam at a non-90˚ angle.

93. The web material structuring belt according to any of paragraphs 1 to 92 wherein the non-termini portion structuring layer material gap seam is connected to a termini portion structuring layer material gap seam at an acute angle.

94. The web material structuring belt according to any of paragraphs 1 to 93 wherein the non-termini portion structuring layer material gap seam is connected to a termini portion structuring layer material gap seam at an obtuse angle.

95. The web material structuring belt according to any of paragraphs 1 to 94 wherein the non-termini portion structuring layer material gap seam is connected to a termini portion structuring layer material gap seam at an angle of greater than 0˚ but less than to 180˚.

96. The web material structuring belt according to paragraph 95 wherein the non-termini portion structuring layer material gap seam is connected to the termini portion structuring layer material gap seam at an angle of greater than 10˚ but less than 150˚.

97. The web material structuring belt according to paragraph 96 wherein the non-termini portion structuring layer material gap seam is connected to the termini portion structuring layer material gap seam at an angle of greater than 30˚ but less than 130˚.

98. The web material structuring belt according to paragraph 97 wherein the non-termini portion structuring layer material gap seam is connected to the termini portion structuring layer material gap seam at an angle of greater than 45˚ but less than 110˚.

99. The web material structuring belt according to paragraph 98 wherein the non-termini portion structuring layer material gap seam is connected to the termini portion structuring layer material gap seam at an angle of greater than 75˚ but less than 100˚.

100. The web material structuring belt according to any of paragraphs 1 to 99 wherein the structuring layer comprises a plurality of non-termini portion structuring layer material gap seam and termini portion structuring layer material seam connections.

101. The web material structuring belt according to any of paragraphs 1 to 100 wherein the structuring layer comprises two or more different non-termini portion structuring layer gap seam and termini portion structuring layer material seam connections spaced apart from one another different distances.

102. The web material structuring belt according to any of paragraphs 1 to 101 wherein the structuring layer comprises three or more different non-termini portion structuring layer gap seam and termini portion structuring layer material seam connections spaced apart from one another different distances.

103. The web material structuring belt according to any of paragraphs 1 to 102 wherein the structuring layer is void of overlap seams.

104. The web material structuring belt according to any of paragraphs 1 to 103 wherein the structuring layer comprises a single continuous non-termini portion structuring layer material gap seam.

105. The web material structuring belt according to paragraph 104 wherein the structuring layer further comprises at least one termini portion structuring layer material seam.

106. The web material structuring belt according to paragraph 105 wherein the structuring layer comprises a plurality of termini portion structuring layer material seams.

107. The web material structuring belt according to any of paragraphs 1 to 106wherein the structuring layer comprises a plurality of non-termini portion structuring layer material gap seams.

108. The web material structuring belt according to paragraph 107 wherein the structuring layer further comprises at least one termini portion structuring layer material seam.

109. The web material structuring belt according to paragraph 108 wherein the structuring layer comprises a plurality of termini portion structuring layer material seams.

110. The web material structuring belt according to any of paragraphs 1 to 109 wherein the non-termini portion structuring layer material gap seam is oriented at an angle

104. The web material structuring belt according to any of paragraphs 1 to 110 wherein the structuring layer comprises a single continuous non-termini portion structuring layer material gap seam.

105. The web material structuring belt according to any of paragraphs 1 to 104 wherein the structuring layer further comprises at least one termini portion structuring layer material seam.

106. The web material structuring belt according to any of paragraphs 1 to 105 wherein at least one structuring layer material strip comprises a termini portion structuring layer material seam that comprises a gap, abut, overlap or interlock seam.

107. The web material structuring belt according to any of paragraphs 1 to 106 wherein at least one portion of the structuring layer material comprises a non-termini seam comprising an abut, overlap, or interlock seam

108. The web material structuring belt according to any of paragraphs 1 to 107 where a distance between at least 2 termini portion structuring layer material seams is 0 to 50% of the belt length

109. The web material structuring belt according to any of paragraphs 1 to 108 where the structuring layer comprises cast, 3-D printed, extruded, woven or laser engraved material

110. The web material structuring belt according to any of paragraphs 1 to 109 wherein the structuring layer and the gap seam comprise a pattern.

111 The web material structuring belt according to any of paragraphs 1 to 110 wherein the structuring layer comprises a discontinuous, continuous, or semi-continuous pattern.

112. The web material structuring belt according to any of paragraphs 1 to 111 wherein the structuring layer comprises a plurality of termini portion structuring layer material seams.

113. The web material structuring belt according to any of paragraphs 1-73, 75-77, 79-87, 90-112 wherein the non-termini portion is not associated

Further Definitions and Cross-References

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40mm” is intended to mean “about 40mm.”

Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.