Ultrasonically bonded multilayer form and methods of making same

Abstract

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

What is claimed is:  
     
         1 . A multilayer form comprising: 
 at least a first layer of material;    at least one non-fluid compound disposed on a surface of the first layer of material;    at least a second layer of material disposed on the non-fluid compound such that the non-fluid compound is disposed between the first layer and the second layer of material; and    the first and the second layer of material being ultrasonically bonded along a pattern, the pattern traversing at least a portion of an outer surface of the first layer and at least a portion of an outer surface of the second layer of material when bonded such that movement of the non-fluid compound between the first layer and the second layer of material is restrained.    
     
     
         2 . The tape of  claim 1  wherein the pattern includes a plurality of lines.  
     
     
         3 . The tape of  claim 2  wherein the plurality of lines defines one or more shapes.  
     
     
         4 . The tape of  claim 3  wherein each of the one or more shapes defines a volume to contain an amount of the at least one non-fluid compound.  
     
     
         5 . The tape of  claim 2  wherein the pattern includes a repeating and substantially uniform pattern such that the plurality of lines defines a plurality of substantially similar shapes.  
     
     
         6 . The tape of  claim 5  wherein each of the plurality of substantially similar shapes defines a volume to contain an amount of the at least one non-fluid compound.  
     
     
         7 . The tape of  claim 6  wherein each shape defines a substantially similar volume to contain a substantially similar amount of the at least one non-fluid compound.  
     
     
         8 . The tape of  claim 1  wherein the first layer of material defines substantially similar dimensions as the second layer of material defines.  
     
     
         9 . The tape of  claim 1  wherein one of the first layer of material and the second layer of material includes a layer of nonwoven material.  
     
     
         10 . The tape of  claim 10  wherein the layer of nonwoven material includes a layer of material selected from the group consisting of a spun bonded nonwoven fabric, a spun bonded melt blown spun bonded nonwoven fabric, a spun bonded melt blown melt blown spun bonded nonwoven fabric, a melt blown nonwoven fabric, a nonwoven nylon, a carded nonwoven fabric, a plastic, a polyester polyethylene terephthlate, and combinations thereof.  
     
     
         11 . The tape of  claim 1  wherein the at least one non-fluid compound is selected from the group consisting of granular compounds, particulate compound, powders, finely divided materials, and combinations thereof.  
     
     
         12 . The tape of  claim 1  wherein the at least one non-fluid compound is selected from the group consisting of moist compounds, moist pastes, semi-solid compounds, gels, waxes, and combinations thereof.  
     
     
         13 . A method of forming a multilayer form comprising: 
 providing at least a first sheet of material;    dispensing an amount of at least one non-fluid compound on a surface of the first sheet of material;    providing at least a second sheet of material and disposing the second sheet of material on the surface of the first sheet of material such that the at least one non-fluid compound is disposed between the first and the second sheets of material to form a web;    impinging at least a portion of a first outer surface of the web with ultrasonic waves; and    printing a pattern on at least a portion of a second outer surface of the web such that the first and the second sheets of material are bonded along the pattern.    
     
     
         14 . The method of  claim 13  wherein the first sheet and the second sheets of material are bonded therethrough along the pattern.  
     
     
         15 . The method of  claim 13  wherein the pattern traverses at least a portion of a width the web defines.  
     
     
         16 . The method of  claim 13  wherein the pattern includes a plurality of lines.  
     
     
         17 . The method of  claim 16  wherein the plurality of lines defines one or more shapes.  
     
     
         18 . The method of  claim 17  wherein each of the one or more shapes defines a volume to contain a portion of the at least one non-fluid compound such that movement of the at least one non-fluid compound between the first and the second layers of material is restrained.  
     
     
         19 . The method of  claim 16  wherein the plurality of lines defines a repeating and substantially uniform pattern of similar shapes.  
     
     
         20 . The method of  claim 13  wherein impinging the portion of the first outer surface of the web with ultrasonic waves includes impinging the portion at about substantially a same time as printing the pattern on the portion of the second outer surface of the web.  
     
     
         21 . The method of  claim 20  wherein the portion of the first outer surface and the portion of the second outer surface of the web are substantially opposite one another and aligned.  
     
     
         22 . The method of  claim 13  further comprising impinging at least a portion of the first outer surface of the web with ultrasonic waves and contacting at least a portion of the second outer surface of the web with one or more cutting devices such that the cutting devices cut the web therethrough into one or more multilayer forms.  
     
     
         23 . The method of  claim 22  wherein impinging the portion of the first outer surface of the web with ultrasonic waves includes impinging the portion at about substantially a same time as the one or more cutting devices contact the portion of the second outer surface of the web.  
     
     
         24 . The method of  claim 23  wherein the portion of the first outer surface and the portion of the second outer surface of the web are substantially opposite one another and aligned.